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electrochemical machining machine in use
electrochemical machining setup

OUR PROCESS

Voxel has developed a pulsed electrochemical machining (PECM) process that enables unique geometries, better tolerances, and faster machining times than competing manufacturing technologies.

PULSED ELECTROCHEMICAL MACHINING 

Pulsed electrochemical machining (PECM) is a non-contact, unconventional machining process based on the principles of electrolysis. The machining operation involves a tool (the cathode) in the inverse shape of the desired workpiece (the anode).

As the tool moves towards the workpiece surface, it machines the workpiece into the complementary shape of the tool. This occurs as a pulsed DC current is applied, allowing for high precision and superior surface quality. At the same time, an electrolyte is pumped between the cathode and anode at high speed, removing dissolved metal and heat. 

 

The result is an operation capable of producing a burr-free 3D shape with no tool wear in alloys that are difficult or impossible to machine through traditional methods.

diagram of electrochemical machining components
electrochemical machining step 1

Step 1

Cathode and anode are

set up and electrolyte is pumped between the

two parts.

electrochemical machining step 2

Step 2

As the two pieces move together a pulsed DC current is applied to the anode and cathode.

electrochemical machining step 3

Step 3

The flowing electrolyte removes heat and waste products from the gap.

electrochemical machining step 4

Step 4

The workpiece is machined into the complimentary shape of the cathode tool.

electrochemical machining step 5

Step 5

Part is complete with no need for any secondary processing, burr removal,

or polishing.

Metal potentially able to be used in electrochemical machining

MATERIALS & PECM

4140

A2 Tool Steel

Al MMCs

Aluminum 6061

Aluminum 7075

AMZ4

Brass

Bronze

CMSX-4

Cobalt Chrome

Copper

Ferrium C64

GaSb

Germanium

Haynes 230

Inconel 625

Inconel 718

Inconel 738

Inconel 740h

InSb

M4 Tool Steel

MarM247

Molybdenum

MP35N

NdFeB

Nickel

Nitinol

Nitronic 60

Pyrowear 53

Rene N-5

Stainless 17-4

Stainless 304

Stainless 316

Stainless 440C

Ti Grade 2

Ti 64

TiAl

Vit105

UNPARALLELED ACCURACY

Creating precision parts from advanced metal alloys is a growing challenge facing our customers.

 

Next generation PECM permits novel designs, produces higher quality parts, and can machine hard or temperature resistant alloys at higher speeds than competing technologies.

 

PECM is capable of machining any conductive metal or alloy and is particularly well suited for those materials that are difficult to machine through conventional methods, such as superalloys. Commonly machined materials include nickel, iron, and titanium-based alloys in a variety of formats such as cast (including single crystal), forged, additively manufactured, and powdered metallurgy.

 

PECM is best suited for high-value metal components in highly stressed environments such as orthopedic implants, surgical tools, turbine engines, turbochargers, rocket motors, heat exchangers, sensors, and energy applications.

Pristine Surface Finish

No recast layer, no heat-affected zones, no burrs

Machining Thin Walls and Microstructures

Ability to machine thin walls and microstructures

High Repeatability and No Tool Wear

High repeatability, no tool wear

Machining 3D shapes in one step

3D shape produced in a single step

High material removal rates

High materials removal rates

GET TO KNOW VOXEL

Learn about the team, policies,

and company values that make us who we are.

REACH OUT

Tell us what you have in mind,

one innovator to another.

Let's shape the future together.

chair in foyer of Voxel's office, where we do electrochemical machining