'Zero Tolerance Machining' with the Wire EDM, Making a Puzzle Cube - Part 2 | US Digital

Our machine shop can cut metal so precisely using our wire EDM that two parts fit together with virtually no gap between. Learn even more about how the process works in our follow up video.
These puzzle pieces are not for sale.
#machining #manufacturing #wireEDM

[@bigmassive2403]

If you start selling those cubes its a gold mine

[@joshandkorinna]

No, def not. Unless they sell them for a grand a piece. It takes them two hours just to make the one cube.

[@LifeonWheels]

@@joshandkorinna that's just the cut time. Just think of all the material handling and grinding for finish.

[@bcshooterfmjprime7540]

@@skrewup7354 mezmo I think

[@PHANTOM-vd2sn]

@@joshandkorinna if I get you one for 200 will u buy it?

[@joshandkorinna]

@@PHANTOM-vd2sn No thats too much. I'd pay maybe 15 bucks for one. This is why it's not economical to manufacture these and sell them. People aren't going to pay what it costs to manufacture them.

[@CDRaff]

Remember when it used to be a common sci-fi trope that the alien's space ship had a door that seemed to appear out of nowhere because the metal was machined to such high tolerances? LOL

[@OGbqze]

Until the tempurate changes and the door is sealed shut.

[@vettebodee]

@@OGbqze We still haven't discovered anywhere near every metal in existence. It's very probable there is a metal out there that is almost virtually unaffected by any thermal changes it would experience in regular use. But melting and forging such metal would also be such a pain.

[@OGbqze]

@@vettebodee that would be awesome.

[@l.h.9747]

@@vettebodee that would be a material wasted on a door. I mean its good if you can see a door if you asl me xD

[@robbiejames1540]

@@OGbqze As a plot point that would be so funny. The aliens arrive and can't get out because earth is a few hundred degrees cooler than wherever they're from.

[@user-fs5hq4dv7w]

I always thought it was just a single cube cut up perfectly, makes a lot more sense this way…

[@dsandoval9396]

That's what I was thinking too, but as soon as they put up the block with the four pieces marked to be cut it made a lot more sense.🤦‍♂️

[@joseppedaia3673]

if you think about it, you can cut very precise, but not indefinetly thin

[@Quicksilver_Cookie]

This would be very nearly impossible. In order to cut anything you need to remove some material. Even if it's a couple of atoms thin. Meaning that a block of material cut in half even with the most precise and wasteful technique will have less material than it did when it was in one piece.

[@ber2996]

well that's impossible because the cutting wire that should be used for that must be a lot thinner than a strand of hair which is sure going to be not strong enough to cut steel, I always thought it's separate parts and I'm right

[@chaklee435]

@@Quicksilver_Cookie shears obviously not possible for the metal cube we're seeing here, but in general. A block cut in half can have the same amount of material after the cut.

[@patrickturner2788]

Nice to see again. I was a plastic injection mold maker and specialized in Ram EDM. I then took a job with a Swiss company named AGIE. I bought a wire EDM from them in 1985. Was in business northwest of Chicago for 18 years. Owned 11 machines over that time. 3 Swiss AGIE and 3 Fanuc were on my floor at all times. Retired to Jamaica 10 years ago. Thanks to my crew, some of the best programmers and operators their were at the time. Enjoy it's a great trade.

[@aaronm.1998]

Good grief. Go sit down.

[@beforeandafterphotos]

😂😂😂​@@aaronm.1998

[@Jack777Er]

​@@aaronm.1998 have a cry about it kid 🤦‍♂️

[@ABEL-cd2sp]

This is absolutely fantastic. Fully understand why you wouldn't sell them but i can deeply appreciate the insane level of precision and care you guys put into your work.

[@DangerfieldChris]

Everyone wants the cube. But at four hours manufacture time, they’d cost about $1500 a pop.

[@jamesscott6753]

@@RoadnTech i dont think you can math

[@reidb9422]

@@RoadnTech the cost of the block and wasted material is minimal in comparison to the cost of machine time, the operators wage and the programmers wage as well. This does not even consider the time that it takes to actually prep the stock and square it up before it is even usable by the machinist. The material is hardly the issue with the cost of precision milling of any sort, not just wire edm. Unless you are milling something like titanium or some other costly metal, steel and aluminum is relatively very cheap.

[@josephk1342]

@@RoadnTech “easily” What are your credentials? Because it really seems like you’re talking out of your ass

[@Crypto-Legend]

@Joseph K If you spend more than $250, you're an idiot

[@josephk1342]

@@Crypto-Legend what are you basing that off of?

[@JohnLow7627]

As a technician that does plastic mold manufacturing, that EDM looks really cool compare to ours

[@loganaick386]

🌞⭐⭐⭐⭐⭐I friends I am india if want this job low cast high quality plz tell me we provide support , (press toll spares punches and dies and plastic molds accessories) our concern have edm sprk, w edm, surface grinding, cylindrical grinding, and extraa ..

[@polkyys]

How much a molding machine cost? And what s brand and model name ?

[@VenturiNL]

@@polkyys There is popular brands like Arburg and Engel, these machines usually cost around 30,000 up to 100,000 (or more) dollar.

[@wakuwaku6647]

@@polkyys normally people who buy this type of machine is rich old guy who worked in this field for 30+ years, or an owner of big company Not people like us 🤣

[@uiopuiop3472]

@@wakuwaku6647 i wanna buy edm machienne for 300 euro but noone sells it for only richguys buy

[@svxworld]

So satisfying to watch them line up, just imagine how it would feel like when holding it in the palm of ur hand 🥺

[@peteroleary9447]

We (and many shops) been making cool, close fitting stuff with WEDM every day for years. For making specialty tools and molds for industry. Making tangible and useful things is a lot more satisfying than spreadsheets and financial statements.

[@x2e4]

Ikr 💆‍♂️

[@wackyvorlon]

I got to handle one at a trade show once that was like that but a very complex spline instead of puzzle pieces. Actually feels pretty weird, when trying to put it together any slight misalignment will stop it. You have to kind of jiggle the pieces to get them to fall into the right place, then it just glides down.

[@Hexra_]

I love how the concept is literally just for show (in a good way) since it tells clients of what their company is capable of

[@Mrhphs]

They don’t make it to sell. It’s an industry flex. Nice work gents.

[@collinclark8591]

My job is in mold polishing. These videos are nice to show exactly how much precision is needed for the molds, just to make a little plastic part. Many people don't understand how complicated these pieces can be!

[@loganaick386]

I friends I am india if u want this kinds of job low cast high quality plz tell me we provide support , (press toll spares punches and dies and plastic molds accessories) our concern have edm sprk, w edm, surface grinding, cylindrical grinding, and extraa ..

[@freemansfreedom8595]

Not only that, but also how important this is for any mass manufactured product and one of the parts that make economy of scale shine.

[@wizewizard1840]

One complete mold for our plastic injection molding machines costs 600.000$ for a reason.

[@heroinmom153]

How long does a mold made to this tolerance requirement typically last? Or rather, how many plastic pieces can typically be made before the mold is considered worn?

[@StrsAmbrg]

​@@wizewizard1840why is your mold so expensive?

[@MrCozin-kd9mb]

You guys are the real deal for sure! Congratulations on the beautiful explaining material and the work itself. I understand that making those cubes is an extensive process and they'll not be cheap, but it's a shame for us not to have them available. Lol I believe that more satisfying than watching it would be handling this wonderful piece of machinery. That's magic.

[@deusexaethera]

I can't be the only one who thinks it's incredibly rude to show off a toy like this but refuse to sell it.

[@aperson696]

no it costs a ton of money to make these

[@syedmuhammadwasiq2438]

I think pleasure is more important than money 😊​@@aperson696

[@hindesite]

I have a brass and steel Chinese puzzle cube that my father made. Tolerances are extremely close, but yhis was made by hand using hand tools only, chisels and files. It was part of his training as a cadet for the Royal Navy, back in the 1940s.

[@JB-he1jt]

I used to run and program a Mitsubishi FX10K wire edm! Very user friendly and wire breakage was minimal! We had 5 Chevalier surface grinders in a row just just like the on this clip.

[@mr.bulldobs4337]

"The tolerance is 1/10 of 1/1000 of an inch." Thank you freedom units.

[@wizewizard1840]

lmao

[@medicmain3947]

Or .0001 of an inch ,most machines shops use decimal.

[@That_Awesome_Guy1]

They were just trying to emphasize how small it was. Normally you would say a 1/10000 of an inch.

[@AquilaSornoAranion]

At least they're using powers of 10 here. I guess they'll come to their senses sooner or later. Aaaany minute now...

[@XtreeM_FaiL]

1/10 of 1/10 of 1/10 of 1/10 of an inch.

[@wizewizard1840]

Holy f*ck. I have a master's degree in metal working and I'm a professional watchmaker. But I think this is the coolest metal fit I have ever seen.

[@Ramog1000]

oh thank you for the video. This cleared up a misconception I always had about these things. I thought the 4 pieces where basically cut out of the cube that is displayed in the end that would always pose the question of (how were they able to make such a thin cut). With it "just" being a very accurate machining technique it actually makes allot more sense now.

[@curtiswrong]

He goes on to say he does molding which is a fact that hand work is always going to be superior to machinery for high levels of accuracy, mold making or class A automotive spotting is equal to the thickness of liquid in most cases, takes a damn long time but when finished is a an absolutely beautiful relationship between upper and lower dies withing a micron or 2,, theres a reason toolmakers still have jobs🤙

[@alanpudifin7972]

Nice job! I made my own puzzle cube a few year ago from Toolsteel hardned to 60HRC. Still good as new :-)

[@AlChemicalLife]

People are saying sell them but don't understand the actual cost this took to make. If they knew they wouldn't want to buy something like this for that price. I work with edms all day every day...

[@worstgamer1162]

Well, I wish they could but I understand so it’s aight

[@GRAITOM]

I would happily pay 100-200$ for one of these things.

[@AlChemicalLife]

@@GRAITOM doubt you will get one for that price. These are holding 10ths , making a part to the 10th isn't cheap

[@JohnLow7627]

Yeah, EDM is a slow and precise machine

[@RoadnTech]

Aye, let rich people spend their money and auction them. Would be a profitable opportunity for the marketing department for a limited run

[@Kikithesaltywitch]

This is so cool, thank you for making a part 2!

[@jerryhammack1318]

Beautiful performance with the quality and excellent fit for precision parts! Metal machining has come a long way with modern technology!

[@fxgamer-11yt]

Those puzzles pieces could make a killing for yall honestly I'd pay upwards of 80+dollars just for the satisfaction of seeing the seamless cuts like that's just beautiful love the way it looks and just the fact that it a cool novelties toy would bring the value up

[@ninecreekfarm]

Watching this random video like “boy I had a lot of fun working with machines like these at ……. Oh hey this is US Digital!” Used the sinker there to run the first MAE3 molds. Small world. Cheers, family!

[@emd1405]

Guess I'll be making a trip to Vancouver WA for a "tour of the facility"

[@smashyrashy]

And cube theft!

[@aidanbrooks771]

Those tolerances tho 😍 you can’t even tell it’s a separate piece

[@PiGood]

Honestly that is mostly the grinding. I would guess by how free it moves they have about a .00025" clearance in there. Even at that tight of tolerances there is still be pretty visible lines from the clearance. However when you grind it, some material is displaced in to the clearance gap, kind of bridging the gap and effectively making it invisible to the human eye.

[@prozacgod]

I wonder if you could manufacture a Rubik's cube to this sort of tolerance.... Imagine how amazing it would look as it rotated into its solved position with all brushed sides matching and becoming seamless... You could even use bluing techniques to get the different sides to different colors...

[@robbiejames1540]

Might be hard to give individual faces the colours - but yeah, that would be amazing

[@ob2kenobi388]

Problem with that is that you'd need to twist it perfectly, almost down to the atom, in order to do more than one twist.

[@observersnt]

“Engineering is the science of science exactitude “ An “old hand” told me never to forget that when I began my apprenticeship as a shipyard engineering fitter in 1966. He said a chief engineer told him that when he had gone to sea as a youngster himself It will always be true in an ever increasing way Thank you

[@Croissinate]

This is the sequel I've been waiting for all my life

[@Kasperhp7410]

I'm quite amazed by how smooth theese zero tolerance pices move past each other. I used to be a blacksmith and have experience with laser cutters and sheet metals but that dosn't compare to what a mill or a brass saw can do to a block of steel.

[@Razuri_Zeev]

Very educational video!!! You earn a subscribe! Straight on point, informative, editing is pro level!!! No annoying add-ons. And entertaining to watch while learning! Thank you very much!

[@itsaperionasentinel5446]

“Hey do we sell these?” “NO!! AND STOP FUCKING ASKING ME THAT!!”

[@Valery0p5]

I know everything you showed in the first minute of the video is standard milling equipment, but it reminds me a lot of my uncle... He had a lab with all this stuff in his garage, it really felt like he could build everything when I saw it a couple of times as a child. Man...

[@shottysteve]

i appreciate this ad. very honest that its an ad, while still entertaining and educational

[@adliirfan2424]

This wasn't ad, this is tutorial. XD

[@joselindiaz-abreu7810]

🙂Greetings! 🤔Whenever they are available to purchase! I'll be some of the first people to aquire one. 😃🤩It will be on a glass display case at my home for me and others to admire! 😇🌇Have a beautifully blessed day!

[@loganaick386]

I friends I am india if want this job low cast high quality plz tell me we provide support , (press toll spares punches and dies and plastic molds accessories) our concern have edm sprk, w edm, surface grinding, cylindrical grinding, and extraa ..

[@user-ie2qw6ce9e]

Великолепно! Респект и уважение! Прекрасное оборудование. Высокий уровень эксплуатации.

[@loggers5500]

Ok... imagine this but on a massive scale. Like body panels for a car... I don't know if it's just me but the idea of 0 tolerance flush panels makes me unreasonably happy

[@jfangm]

Nope. Not worth it.

[@robbiejames1540]

You'd never be able to keep it that way with the amount of thermal expansion on something so big. There'd be gaps in the winter, and it would jam in the summer.

[@unrealvibe98]

IMAGINE

[@penelo9114]

This is a very good flex for a company. That's one ad I wouldn't be mad to watch on YT.

[@Drache832]

As a former machinist there is only one thing that bugs me about this video, even though some might see it as minute: Please NEVER tell anyone the water is "safe to touch". It is less dangerous to touch, true. Nothing will happen if you touch the water AND everything goes to plan (which is the usual case), but the machine itself still isnt safe at all if the security measures fail. Just a little safety nitpick, great video

[@Ash_lee613]

Okay, so the better question is: WHEN are you going to start selling these?

[@kobalov1]

Can hook you up with one, 1700$

[@loganaick386]

@@kobalov1 if u want that ?

[@sid28]

if you emailed them offering a couple grand they might, because it would cost a couple grand.

[@yoopersen]

They would lose a lot of money on every one they sold

[@BakeBakePi]

0:47 AYO sussy?!

[@thebigcheese8715]

I've only seen these beauties of a machine just a few times but, now I'm just plain curious if it'd be possible for it to machine/cut the threads for a bolt like a die.

[@Proud2bmodest]

It's possible by using an electrode shaped like a tap split longitudinally to cut internal threads. The electrode would cut just like a tap by first cutting threads on one side and then slowly rotating while moving down similar to a thread cutting mill. A similar technique could be used for external threads. I assume copper or brass would be used for the electrode to create the fine details. It's probably not very practical and a thread cutting mill would be faster and easier.

[@schlenbea]

I always thought it was cut out of the same 4 pieces, just put together. I didn't realize it was from a larger block... That makes way more sense now!

[@alexsheppard237]

I always keep at least a ± 1 thousandth, can't ever imagine getting ±0 at multiple curved angles. Amazing work here!

[@johnbirkholz994]

Newer wire machines can hold tolerances of ±0.00002" (twenty millionths!) but it takes something like 7 or 8 passes with progressively lower power settings on the cut.

[@rkthakur7016]

Impressive work and technological genius. Hats off

[@FisherBernard]

The weirdest part of this video is seeing such a high tech process, while hearing "one tenth of a thousandth of an inch". Thankfully google could translate it to microns for me.

[@jfangm]

That's .0001 inches, or 0.0025 mm - insanely small, considering most machining applications only require a tolerance of .005 inches (~0.01 mm).

[@nelsonwilkins347]

I would pay a lot for this please sell it come on take advantage of this 😭 theres no downside for you all make it a holiday thing!

[@profex.]

According to a comment on this video, these cubes would cost $1500 each because they're crazy expensive to make.

[@jfangm]

@@profex. Tight tolerances like this would cost about 10 grand apiece.

[@battles151]

Although it is very cool to the normal person, having designed and programmed thousands of parts via mill, lathe, grind and wire..this is everyday life for me. Thanks for sharing!

[@BasicFolders]

US Digital: These puzzle pieces are not for sale. Me: *THEY SHOULD BE.*

[@guitarsknivesheavymetal]

Saw these type of block precision in one of BLUM factories in austria.i was so curious on how did they do that.

[@jimmyc6686]

2:22 looks like so much fun! Wish you guys would sell those!

[@peteroleary9447]

You couldn't afford it.

[@sid28]

it would cost 1000s of dollars. If you emailed them and said 'ill pay you a couple grand to make one for me' they might do it, but it doesn't make sense on a commericial scale.

[@annaoldfield2298]

this is amazing I am so amazed for how hard you work for it😮

[@hibahprice6887]

It is made from different pieces of steel. There is no gap in the details of about 0.05 mm, plus a 0.1 wire will make a cut with a thickness of 0.15

[@2xKTfc]

I have wondered forever how wire EDM makes these perfectly fitting parts with basically zero kerf...it's two different parts both made to tight tolerances, but not extremely small kerf d'oh! Silly me. But all the same, EDM is a fascinating method with outstanding results. Cheers! :)

[@davidmontroy3408]

The extremely tight tolerance is one thing, but how do you counter oxidation, forming a layer of rust? Even a slight temperature difference between these parts, would affect their mating fit. Can these methods be applied to materials like titanium or tungsten?

[@TucsonDude]

Make it out of Iridium.

[@quint3ssent1a]

I love how working discharge machine produces smoke and bright light. You can say it's magic and you won't be far off.

[@arunkennedy9267]

So this cube is the equivalent of nib on a saw. For context nib in the saw signifies how skilled the blacksmith who made the saw is. And this cube shows how much precise product this company can make.

[@himesjon]

Thank you for all you do in our community!

[@LS26Productions]

I don’t mean to be that guy but in machining if there’s anything I’ve learnt it’s that there’s ALWAYS some kind of variation with the measurements. But sometimes it can be so small it’s a microscopic difference.

[@beachboardfan9544]

You SHOULD sell them! I've been trying to get my hands on some EDM parts like that for years, to pass around to students in lecture.

[@SilenceBot]

Bro they would probably cost $1000 dollars (no joke, it takes 4 hours to cut it.)

[@beachboardfan9544]

@@SilenceBot Yea I believe it

[@erenyeaga9331]

mad respect for not making this 30 minutes long

[@h0esway244]

I will never ever in my life use this information for anything but man was I entertained

[@thegreatestoffools]

Making this cube is such a stroke of marketing genius. They've made their company and methods viral to a whole audience of millions, when before only a handful would have ever heard of them.

[@veryfreehabbocoins]

I’m IT at a large automotive injection molding facility that also makes and services molds for other companies (dual company, one building) and some of the tech we have is insanely cool

[@Speed001]

Whoever's managing this, good job.

[@Sanatni_Sanemi]

In my internship I operated all three machines surface grinding m/c milling M/C and edm now at my job I am vmc operator ❤

[@RickNeffConsultant]

Great video of using a Mitsubishi EDM machine from MC Machinery to make really high-tolerance parts.

[@iangraham6730]

Surface grinding them in position really sells it 👌

[@themetalman9881]

I am a fan of technology watching this makes me so comfortable and relax!

[@spotoncam3640]

For we non engineers, this explanation helped understand better - Thanks 👍🙏

[@Assault_Butter_Knife]

I know nothing about machining but dear god this thing just looks and feels so right

[@veselinjokanovic3032]

"1/10th of a 1/1000th of an inch." Imperial at its finest.

[@kyu2813]

Thank you for this easy DIY tutorial. Now I can make there cubes at home.

[@ACommenterOnYouTube]

The real genius is the man that invented the machine

[@Carbon3915]

全く継ぎ目が見えない凄すぎる

[@EleanorPeterson]

I understand how the EDM process works, but it still seems like magic to me...

[@ryaneditor567]

Wow! That's very interesting! I'm gonna subscribe right now.

[@pmop1432]

A complete masterpiece 🤌🏻

[@sibinsaithomas]

This cube is so satisfying to watch

[@DF-wl8nj]

Fun fact: this cube fits together very precisely, but if they fit together perfectly at the atomic level then the metallic bonding between atoms of different pieces would actually reform when the piece was put together. So, there is actually a cap where making the cut more precise is less useful.

[@etwas47]

I didn't think i could see that kind of precision in my life

[@chromatic91]

My old teacher once taught me a bout tolerances and how some tolerances are so small that they only fit precisely when the room temperature is the exact correct! it's fascinating

[@jamesmc1600]

Imagine working to this level of precision and using inches 😂

[@nickickz]

I’d dedicate my life to learning to work with machine like this.

[@wakuwaku6647]

Good luck, usually this machine used in shopmold, plastic industry

[@hnorrstrom]

Starts out super technical and scientific. Goes on to talk about thousands of an inch....

[@emileesuchil5874]

The grinding part made me have the "this is my kingdom come this is my kingdom come" song In my head

[@Komeuppance]

People will suffer vertical video just to see more of that cube, apparently.

[@billmarrufo]

Tolerance is generally confused with clearance but both concepts are totally different in engineering. Tolerance is the permissible range of variation or deviation from a nominal value of any dimension. It is a design specification. Clearance is the real physical distance between two surfaces. Obviously, to obtain very small clearances, tight tolerances must be specified and met. As clearance approaches zero, the surfaces tend to stick to each other, they do not slide. In injection mold design and manufacture, there are critical surfaces that need to slide freely when not subject to pressure and immediately after, reach metal to metal contact under load.

[@miladinde]

wooow god🤯🤯 very beautiful, how is it! How many errors have been reduced, there is no error at all, God

[@dani.alvaro9280]

2:14 As you can see, the contours of the individual cubes are still clearly visible before sanding. And this is exactly where the secret lies. You grind or mill over the contours of the cubes when they are put together so that the resulting burr covers the gaps.

[@SilentHillFetishist]

That´s also the way to hide welding, when a joint didn´t pass.

[@ApertureAce]

I don't know why I thought all of those puzzle pieces were cut from the same block directly adjacent from one another. It makes much more sense that each piece is cut individually so they can link up after the cut rather than being cut already interlinking.

[@TMP912]

I recently bought a Zigzag wire edm puzzle. You can see the seams slightly. Was a bit disappointing, but it's still really cool.

[@SilentHillFetishist]

If you mill over it, the seams may seem smaller, because they become ridged.

[@Sl4yerkid]

I wish this was as good as it looks, like this was made from one cube and cut, rather than 4 separate parts put together.

[@joshuabeall3092]

They describe a worm that can cut stone with precision in ancient tales. Some places have this precision but they didn’t have this type of machinery. It’s interesting to watch this thread cut like this after seeing those sites around the world. Is this the worm they were referring too?

[@DantesAlvesdeSantana]

Nunca vi cavacos de edm tão grandes como ele mostrou😁

[@test-rj2vl]

Imagine being able to do your DIY projects at home with that amount of precision.....

[@owenjj93]

The one time I hoped it was an ad and you disappoint me..

[@supercat380]

Engineering precision at it's finest

[@walterfristoe4643]

I saw a video short, and had to come check it out! Awesome!