Wire EDM machining simulation

The problem

In wire EDM machining, operators need to verify complex cutting paths before running the machine. An incorrect toolpath can damage expensive workpieces and waste hours of machine time. The challenge was to give operators a clear, reliable preview of what the machine will actually do — directly on the machine’s interface.

What we built

We developed a 3D simulation application that visualizes the complete wire cutting process in real time. The operator can see the wire movements, verify the toolpath against the workpiece geometry, and preview the finished part with realistic rendering — all before the first cut. The application was built using our Eyeshot-based 3D engine, which allowed us to deliver high-performance visualization within the constraints of an industrial embedded environment.

Result

This project was carried out in collaboration with GF AgieCharmilles, one of the world leaders in EDM technology, and the application is deployed on their latest generation of machines.