I 3D printed a 4-axis wire EDM machine that can cut anything conductive

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Fulfillment of Powercore V2 is expected to begin this month of May. Half of this batch has been sold. We will be maintaining rolling production. We expect to begin accepting international 🌎 sales soon, using third-part distributors.
Thank you to all of our Powercore V1 Kickstarter backers for helping to launch our company, and with it a new generation of wire EDM machines!
Personal rants & ramblings on ✖ :
/ chemist_john_

[@lucyhalut4028]

This is amazing! Great work.

[@trivalentclan-mizar9591]

Rare? My father bought a used one in 1980 for his Tool & Die shop, my older bought two more in later years. Many other shops had newer Wire EDM machines. I learned raw G code programming using a teletype for our first wire EDM machine. One of my coworkers at a research laboratory out sourced his parts to machine shops using wire EDM machines.

[@dlynch8668]

Sounds like you’re rare too:)

[@Denasdc]

Ohhh, you fixed left audio channel only. Thank you!

[@conorstewart2214]

I was wondering if I was going crazy and that I had seen it before or if this was someone stealing someone else’s video, but it makes more sense if he just reuploaded with the audio fixed.

[@MarinusMakesStuff]

Hey awesome, I'm definitely going to buy this. One tip, I think it would be really interesting to make some type of upgrade route where the EDM machine can cut its own replacement parts out of aluminium to make it stiffer. So it would be great if that is kept in mind when designing the 3D printed parts. Beyond that, awesome design! I can see a lot of love went into the design of this machine.

[@fladder1]

Would really love to see the actual work flow from design to cutting. Awesome project, as soon as it comes available in Europe I'll order one.

[@MorlockEngineering]

Okay, I will make a video on this.

[@Jon.S]

I feel that software experience is going to be key, if you can get the user experience as noob friendly and approachable as modern 3D printing there’s a huge market of people who’d love this. If the process to get a part machining is esoteric and relies on the user being a CAM/klipper expert then it’s going to be a tough ask for most hobbyists.

[@WeberMachineWorks]

well said Jon.

[@Darnetal57]

Seriously, this is the most excited I've been for the past decade. I'm definitely going to follow this and most probably buy one of these kits sometime down the line, so get ready to have them shipped to Europe.

[@futileskills]

Just found your channel and project for the first time. 100% saving up for this. I can already think of a few projects that my makerspace could use this on. Thank you for putting in all this work ❤

[@M4XD4B0ZZ]

I'll wait for better tolerances. Gratulations gor your achievements so far! Super impressive

[@WeTrudgeOn]

Pure genius. I'm a manual machinist, the only CNC machine I have ever desired is a EDM machine.

[@MikeKasprzak]

Lovely. I've enjoyed the various clips from 3D printer KZbinrs. This is the sort of thing I would love in my workshop (*cough* garage). Will be continuing to keep an eye out.

[@blazehenot2536]

Its going to be wild to see the kind of projects and products that this enables. Your existing non wire EDM machine already opened the door to precision manufactured 2d and stamped parts. adding a whole extra dimension with the capacity for precision rotary manufacturing as well is even more mind blowing! Best of luck in your future endeavors I can hardly wait!!!

[@davidbalfour3390]

Looks great. I'd use button head socket caps where possible so all forces are basically compressive. The countersunk can flare and crack plastic if overtightened, button head are more forgiving.

[@GiulianoMazzina]

Damn, one video and I subscribed. Thats a record. I want to watch the progress of this device and your new company. Congrats!

[@fabienl4979]

Yes exactly my thought, I even subscribed after a few minutes into the video. Well made video, incredible to have access to desktop wire EDM machine (with a 400$ power stystem). Like he said, when I watched the prices back then for the power supply it was really 2-3K. So I'm looking forward to seeing the next version of this machine with great care.

[@738elijah]

I'm very impressed with this project, both in innovation and straightforward, elegant, engineering.

[@MorlockEngineering]

Thank you!

[@runningwitsciss0rs]

Stunning! Been subscribed for a while and the progress is substantial. Keep up the good work!

[@Hukkinen]

Amazing! Saw you guys @CNCKitchen. This as a disruption! Micro-mechanics: gears, watch parts, micro-surgery tool parts, brushless motor stators, gun parts, and injection molds etc. Open source, engineering, and product development at its best! I hope you great times! 😀

[@fabienl4979]

It's not a new type of machine. Watch parts are much more suitable with laser cutting and/or photoetching cutting. The wire has a diameter really not negligeable for micro parts to create. EMD wire machine can achieve incredibly tight tolerences but a micro gear or watch part, laser cutter can do sharp inside/ouside corner with not radius. But I'm totally agreed with you, a desktop affordable wire EDM machine could me incredible, mostly the 400$ power supply. After that it's the precision of the X-Y movement of the machine, rigidity and so on that will dictate it's precision. I'm looking forward to seeing the machine and its price.

[@Hukkinen]

@@fabienl4979 Thanks for the detail. My bad; perhaps only clock parts, then (which actually someone mentioned) ;) Sounds like rigidity is a simple problem. Then again, I have no idea about microscopic tolerances of a dynamic system =)

[@alexross26]

gods work. you are doing gods work. its like a stopgap until real 3d metal printing gets to the consumer level

[@NigelTolley]

Consumer 3d printing, especially with metal (if it ever even happens) will never be as accurate as these machines can be.

[@alexross26]

@@NigelTolley why. rocket engines and jet turbines are 3d printed, I think those industries require accuracy

[@NigelTolley]

@@alexross26 Rocket engines are printed from massive rolls of welding wire by robot arms and turntables. It's very neat - I've seen it happening - but the accuracy is in the millimetre range. The nozzle is metres across. You couldn't fit the machine in your house, even if you took the furniture out, and the 3 phase requirements are rather high. Oh, and it is £millions too. Jet turbines are done via a rather more accurate process, something like direct laser sintering of metal powder heated to near melting point under an inert gas. The risk of an inert gas killing you and your entire family in your sleep is likely too high for most, as well as, again, the power requirements and the costs that start from £200k. Maybe as low as £60k for the very lowest kit. Having said that, there is a nylon 3d SLS/DLS printer coming out soon, running about £2k, dropping the price from the £16k bottom end of the market currently. Micronics. Look them up!

[@baxrok2.]

Congratulations. I hope you sell a million of these!

[@MorlockEngineering]

I hope so too!

[@m4gn3t.0]

I’ve been making EDM since sandstorm… was clearly doing it completely wrong. I am absolutely building one of these thanks you!

[@wzhaicthtaarkyer]

I had no idea wire edm was so rare! Thankfully I work in a shop with 5 of them.

[@plasmashears]

That's what I was thinking too. Not super common, but definitely not what I would consider "rare".

[@Properuppercut]

I worked in a shop with 16 wires for 20 years. Agreed, not super rare in the manufacturing world nowadays.

[@areyounecessary]

Thought the same, worked in a machine shop and we did occasionally outsource EDM work, and I can think of 4-5 shops that were within a 30 minute drive of us. Major metro city, so obviously not the norm, but still. That said, this is still a fantastic idea, especially for those who live in apartments and the sort. Being able to manufacture metal parts in my room without bothering the neighbors is fantastic.

[@Rcmike1234]

They're not rare 😅

[@spacedonutnfo]

Same

[@_droid]

I need one of these! I have been thinking about building one for ages. This project may be it. Can't wait!

[@nickmagerl]

Beautiful work! I'm impressed!

[@bobbyshaftoe]

BRILLIANT. Easy, nobrainer subscription. I am looking forward to adding an EDfrigginM to my capabilities!

[@FruchtcocktailUndCo]

Yes, very good, like a lot. Sadly poor and luckily european, so eagerly standing by and thrilled for the things to come. :D

[@MorlockEngineering]

We will get to you soon.

[@FruchtcocktailUndCo]

@@MorlockEngineering Kisses.

[@Brianwiz]

Commenting to boost the trip vid

[@rotoforge2024]

This is way cool! Great Work Rack Robo!

[@TerenceKearns]

That's incredible. Fantastic work.

[@charliexwallace]

exciting, always wanted to try one out, so looking forward to getting one. great video too.

[@sapiosuicide1552]

My lord this a revolutionary, incredible work

[@MorlockEngineering]

Indeed. This idea has the capacity to change the hardware world.

[@bradlesc1000]

This is actually crazy. Awesome.

[@joelopenshaw8854]

Amazing to see this! awesome work

[@punjabik]

Amazing machine. Wish you the best

[@Sapient_Pearwood]

This is simply amazing to see!

[@josearnaldopinheirodossant7712]

Ohhh, very good, I worked doing mechanical projects and drawings for the first wire edm made in Brazil, it was long time ago, 1980. The electronics was made for a friend, he is electrical engineer, i belive this machine is working 'till now, was usede a Diadur CNC 2 axis only . . .

[@mattheweasterling7558]

Congrats on developing a game-changing machine! When are you guys looking to expand the team 👀? I’d love to contribute to a technology that will change manufacturing as we know it!

[@TheEdgeOfInnovationWorkshop]

Nice work! Following your work! And subscribed.

[@amandahugankiss4110]

hell of a power supply there fella. beautiful.

[@MintMacelodeon]

I'd want a more 2d axis version, designed specifically for sheet metal. From watching this video (no further knowledge) that would be the best use case for this type of machine.

[@Clark-Mills]

On my infinite bucket-list... but a hat-tip to you for doing a decent job! Thank you.

[@MorlockEngineering]

You are welcome. Thank you for buying me lunch!

[@captainclay8938]

This is Stanley Meyer level knowledge

[@lokiwartooth1138]

This is gonna change the 3d2a space forever

[@kayboku7281]

What is this Voodoo magic? I have just purchased my very own workshop and planning the machinery right now! THis is definatley going to become part of the landscape!

[@clytle374]

This is awesome. I'll be looking into this and following along. A wire chopper is a very good idea. I watched a guy drop a used wire spool and end up needing is calf muscle put back together.

[@guilhermebechtinger]

Great work!

[@samrix5793]

Very interesting, i didn't see the Kickstarter but interested when it comes out. How often does the wire break mid cut and how easy is it to thread, is there a way it can auto thread?

[@ced3098]

Nice project , just take in consideration water shall be pure and filtering is a crucial parameter on wire EDM , aluminium is easy to cut but worth to filtering

[@MorlockEngineering]

We generally run 10 micron filters on our 100 PSI flushing pump.

[@goawaybaizuo]

I personally dont have any uses for this, but I'm tempted to get one just to help out. This is amazing

[@robertharper3754]

This is so cool!!!!

[@Lolatronn]

With that Fith axis you could in theory cheaply make a lead screw for a 3d print plastic recycling machine if the tolerances are tightened up more. Then all you would need is a grinding machine which all you would need to do is cut out some gears and make a sturdy attachment for them.

[@TheRainHarvester]

Awesome! I created "GatorCAM for cnc" with slow feed speed capabilities to allow for EDM! You may really like it!

[@neonblowfish]

Nice job!

[@davidapp3730]

An amazing project.

[@BradKwfc]

Ohhh this is so cool. I would definitely buy one!

[@xorfive]

Looks really well designed.

[@MorlockEngineering]

Thank you.

[@gonesilent2814]

blown away with the sexy design of this.

[@i-refuse-to-set-a-username]

This is incredible

[@guyb7995]

I can cut and make lots of things at home with consumer 3D printers and laser engravers/cutters (Fiber & C02) but metal is not one I can really cut, expect for 0.2mm AL card.... This is an amazing development for home makers, well done!

[@firefighter519]

This is awesome! Looks less difficult to build than the Voron 2.4 r2 I'm currently building.

[@BrentLeVasseur]

This is brilliant! Is the power core sold separately from the EDM Machine or does it come with it?

[@joseantoniosalazar4640]

Its beautiful

[@jbrownson]

Very interesting project

[@diditwork370]

I have a couple thousand hours on professional EDM and this excites me very much. Little tip, even if your hardware is flawless, it's all about the controller and software. My Voron has single micron repeatability but it's useless without correct compensation.

[@MorlockEngineering]

Yes. I agree.

[@michaelmueller9635]

Imagine, you could essentially print a planetary gear box with it. Maybe it wouldn't be efficient and time-consuming, maybe some flaws. But as a demonstration in practice, it would be very impressive.

[@elanjacobs1]

Not with those tolerances. You want to be in the 5-10 micron range, not 50-100.

[@hamedsadeghizadeh6660]

Great work

[@martindieux]

I have to say that this project is really impressive. I come from a CNC Kitchen video and this catched my eye. Got to do my own research to get here. Let's boost the algorithm. This is real work of art and engineering combined. I work in plastic injection moulding and I have to design the electrodes, many of which are wire edm cut. I would love to buy one, or maybe wait for the industrial scale one. I would also love a video of the 3D assembly. This project has future.

[@MorlockEngineering]

Thank you. What do you mean by industrial?

[@TheNerfherder1000]

This, and the SLS 3d printer thats hitting the consumer market are literally game changing. At home manufacturing is finally becoming a reality.

[@thewyliestcoyote]

This is awesome! Have you tried cutting tungsten carbide?

[@asidesigner8542]

Thanks for sharing, if you make some videos telling the theory of operation of the power supply i have good expertise to suggest improvements, also I may have some tricks in my hat to lower the PCB BOM cost

[@LeviathanPits]

Wow! Bringing this tech to the hobbyist is incredible. For small to mid sized workshops, do you think it's possible to scale this up? Here's the dream: being able to cut standard >12mm thick steel sheets at pace with insane tolerances (without having to fork over silly amounts of money for laser cutting equipment), and keep floor space usage minimal.

[@V1P3RSlab]

LOOOOOve your stuff !!!! hope to get one as soon as i can

[@MorlockEngineering]

Thank you!

[@noway8233]

Wow , very cool machine ,impresive work, this machines ,the big ones cost a lot of money ,i think there is a market there for litle but usefull machines like this

[@ethansmith7]

Hello, will there be a BOM and/or videos on how to build one of these? Or will it be kept closed and you just have to buy the kit? In particular, what can I do if I already have the v1 power supply and would prefer not to re-purchase?

[@alphawhiskey3311]

When do you expect the 50 micron machine kit to be avaliable? Looking for 0.001" in accuracy

[@kimyasolhjo1763]

can't wait to order powercore v2

[@kylebija]

I'd love to build one!

[@astebbin]

Awesome. Is it possible to recover electrode material from the water bath?

[@inochifumetsu]

Nicely done. Let me know if you ever have a use for a coop student!

[@WildThingss]

Incredible

[@BuildSomethingAuto]

This is very cool! Id love to see an applications video where you show what this can be used for. Any future plans for a toolhead to do conventional EDM instead of just wire?

[@darkenblade986]

""" Hi, this looks like a very fun project, and here are a few tips: =3 * Add a GFI on the power input, and ground your frame properly... or UL will get cranky * Add manual magnetic interlock + emergency stop (i.e. if the power pops back on it doesn't cause injury) * Add a DPDT contactor to be able to invert the work-piece and probe polarity (this is used with a sacrificial surface to resharpen sinker probes) * Klipper is not likely going to work they way you need... because EDM is a closed-loop _adaptive_ non-contact milling process (i.e. the motion may back out of a cut to re-set the ark distance, adjust feed rates to prevent excessive surface pocking from over-current, and drop voltage to minimum to localize the cutting line.) LinuxCNC/EMC people have done numerous custom machines over the years, but the kinematics require a reasonably powerful PC to do 3+ axis. * most EDM systems I've seen use copper coated molybdenum wire * Many papers have concluded for wire EDM it is best to run 3A to 10A , 60v to 130v, 1MHz, and 30% "on" duty cycle. (Note: the FCC EMI rules are a $1m fine, so a fish tank likely won't do...) * most EDM have a dry touch off process, and only fill the tank with liquid just before a run * most modern EDM out of Japan can self thread there own wire to repair breaks or do multiple islands * bearings and ruby wire guides are standard consumable parts * helical milling spiral-cutter flutes or threaded-holes in carbide is still done in the USA * Contact the CAM tool box author for FreeCAD. I met him during my project days, and he is a nice community minded person. Don't splatter the RF spectrum... I guarantee you some local radio operators will find your machine in minutes. In my country it is a $5k fine and minimum 1 year in jail. This message will be deleted in a few days... Good luck =3 """ - joel_mckay this comment wont be deleted

[@pyro1596]

hahahaha

[@al1sa920]

Let's go, this is very cool

[@InfiniteNesLives]

I’ve already got a powercore. Haven’t gotten around to installing in on my old Prusa. Interested in buying the kit without the powercore whenever you’re able to make that an option. Might consider self sourcing the kit parts otherwise, but that’s probably more hassle than it’s worth..

[@o2lamsps]

Amazing! Great job! Is this noisy when cutting?

[@MorlockEngineering]

No

[@DavidWitkowski]

He's the Josef Prusa of wire EDM - well done

[@ritnerritner1]

This is amazing, please tell me you are working on larger sizes

[@nbolt75]

I am currently going into my senior year in a mechanical engineering degree and would love to discuss the possibility of interning. I’ve taken some introductory CAD classes and have used inventor to design parts and to create some simple assemblies. I would love to further my CAD capabilities and to work on such an interesting, innovative project. Loved the video !

[@m2autoworks]

What are you using for torrids and guide in the heads? What are you using to control the K of the water? Are you doing continuous filtering to prevent arcing?

[@MorlockEngineering]

We are using EDM ceramic wire guides in both the top and bottom tools. Filtration is optional, unless you are doing multi-hour cuts in which a lot of chips are produced. For those cuts, we have found that 10 micron filters work perfectly fine for keeping the water conductivity low. Water conductivity matters much less, we have found, when you are not trying to hit single digit micron accuracy.

[@m2autoworks]

@@MorlockEngineering All very good answers. thank you.

[@thefestivemedic]

Amazing work, are there any plans to add a 'hole-popper'?

[@bransonlariscy4660]

This is awsome, ive looked many times for a mini EDM for my hobby shop. When will it be ready for purchase and how would I go about ordering one? Is there anyway to place a pre order to ensure I can get when as soon as they are released? What the limitations are as far as material thickness and material type such as hardened tool steel, Can you use the wire as an edge finder to locate your part, or find the center of a hole before you start cutting? Great Job!

[@danielkemp4860]

For hobbyist, EDM offers the ability to cut through ANYTHING conductive. The actual accuracy isn’t the vital part, it’s the ability to cut Titanium, or whatever, moderately accurately.

[@TheMuffinMan]

I own a desktop CNC and it's a pain in the ass in so many ways that this solves! Including metal particulates flying everywhere, lubrication requirement, and extremely rigid chassis. And you're telling me you can cut tungsten carbide? My desktop CNC can barely cut aluminum 6061. Great work!

[@troyd-motorsport9933]

Great invention! I love the concept of this, but if I wanted to create a larger one just to cut out a shape (1200*400mm) and through plunge 30, 40mm square holes through 3mm aluminium. I'm guessing the brass rod is the way to go and that won't last for the duration of the cut?

[@anderslagerqvist2642]

Just a note, we have 240 Volts rating in Sweden (Europe). It was 220 decades ago. Now we got 230 in practice.

[@MorlockEngineering]

Yes

[@Mrjaydesign]

Cool

[@EvilDaveCanada]

Can you imagine the PC Speed demons going crazy with this thing to make custom solid copper heatsinks? By using pure copper, they can then take a sledgehammer to their failed experiments( to protect their IP if they so desire) before selling them as scrap. A machine like this would also be looked at by the mech keyboard crowd for making custom cases. And think about the metal keycaps you could make with it (my main interest). The cost to have them made (material cost not included) might be more than one of these units costs. Can this unit also do the loss rod (for lake of a better bame) method as well? If it can then holes in side the edges of a flat surface could be done without having to cut from the outside edge or drilling a hole first and then stringing the brass thread through that so as to complete the cut. I know the drilling a hole method would be cheaper on consumables but if the user doesn't care or has other reasons to do so, that would add another level of functionality. As both the power supply & cutting power supply are separate enclosed units, there should be very little problem to get this past the Canadian Standards Association or the European Stardards body. How many litres in 10 US gallons?

[@EvilDaveCanada]

Also can this unit cut brass & bronze? I ask because you are using brass wire and wouldn't like materials fuse/weld together instead of cutting?

[@littlehills739]

thanks for the audio

[@ThingEngineer]

EDM's are nice, CNC machines are evil monsters. Also EDM's are going extinct. Save the EDM's. All joking aside, this a cool project! I hope it does well and has LST and continued development.

[@notfst]

Woah, you're in colorado springs? You guys open for tours or anything? I'd love to come check this out in person!

[@ethansmith7]

Is there a way to ‘punch’ holes completely in the interior of a part? Perhaps using the stand alone rod to make a hole then threading the wire through it? That’s perhaps the biggest drawback of wire edm compared to other methods