Spark erosion, also called Electro Discharge Machining, is useful to machine difficult shapes, as it has been used for decades as a means to create complex forms.
This machining method is typically used when producing intricate pieces. It is a process that creates a specific shape through the use of electrical discharges (sparks). More specifically, this machining process works by removing material from a piece with current discharges between two electrodes that are separated by a dielectric liquid that is subject to voltage. This fluid is both a conductor and a cooling agent during the process.
In order to remove this material, the process converts electrical energy into heat and initiates a melting process within the electrodes. There is no mechanical abrasion with spark erosion.
With this machining process, it is possible to achieve the desired design easily. Because there’s no contact between the tool and the piece, intricate sections or weak materials can be worked on without distortion.