Entry 1: Proposal and first CAD

Wed, 30 Sep 2026 00:00:00 +0000

What it should do

A small sinker EDM machine that copies very fine freeform features into metal. The tool electrode is a conductive negative of the feature. It is lowered into the workpiece while thousands of small sparks per second erode the metal, and the electrode shape ends up in the part. The twist: the electrode starts as a resin 3D print. Resin printers resolve features far below what I can mill, so if the print can be made conductive, the machine turns a cheap print into a precise metal cavity. It works in every conductive material, including hardened tool steel, which is hard to machine any other way.

Entry 2: Machine setup and spark generator

Mon, 01 Jan 0001 00:00:00 +0000

The machine so far

For the mechanics I use parts I already have. A Zaber linear stage (LRM025A) sits on a Thorlabs angle bracket and moves the electrode holder up and down. The workpiece is in a small acrylic tank, and a camera with a lens looks into the gap so I can see what happens.

Linear stage, electrode holder, tank and camera.

The stage is driven by a Zaber X-MCB2 controller. Sparky only sends the commands over RS-232, the controller does the motion itself.

Final Project on How to Make (Almost) Anything

Entry 1: Proposal and first CAD

What it should do

Entry 2: Machine setup and spark generator

The machine so far