'Zero Tolerance Machining' with the Wire EDM, Making a Puzzle Cube - Part 2 | US Digital
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- Опубликовано: 11 ноя 2021
- 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 
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If you start selling those cubes its a gold mine
No, def not. Unless they sell them for a grand a piece.
It takes them two hours just to make the one cube.
@@joshandkorinna that's just the cut time. Just think of all the material handling and grinding for finish.
@@skrewup7354 mezmo I think
@@joshandkorinna if I get you one for 200 will u buy it?
@@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.
Everyone wants the cube. But at four hours manufacture time, they’d cost about $1500 a pop.
@@RoadnTech i dont think you can math
@@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.
@@RoadnTech “easily”
What are your credentials? Because it really seems like you’re talking out of your ass
@Joseph K If you spend more than $250, you're an idiot
@@Crypto-Legend what are you basing that off of?
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.
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.
Good grief. Go sit down.
😂😂😂@@aaronm.1998
I always thought it was just a single cube cut up perfectly, makes a lot more sense this way…
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.🤦♂️
if you think about it, you can cut very precise, but not indefinetly thin
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.
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
@@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.
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
Until the tempurate changes and the door is sealed shut.
@@sbfguy7793 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.
@@vettebodee that would be awesome.
@@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
@@sbfguy7793
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.
They don’t make it to sell. It’s an industry flex. Nice work gents.
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
So satisfying to watch them line up, just imagine how it would feel like when holding it in the palm of ur hand 🥺
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.
Ikr 💆♂️
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.
As a technician that does plastic mold manufacturing, that EDM looks really cool compare to ours
🌞⭐⭐⭐⭐⭐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
..
How much a molding machine cost? And what s brand and model name ?
@@polkyys There is popular brands like Arburg and Engel, these machines usually cost around 30,000 up to 100,000 (or more) dollar.
@@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 🤣
@@wakuwaku6647 i wanna buy edm machienne for 300 euro but noone sells it for only richguys buy
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.
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.
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.
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!
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
..
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.
One complete mold for our plastic injection molding machines costs 600.000$ for a reason.
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?
@@wizewizard1840why is your mold so expensive?
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.
This is the sequel I've been waiting for all my life
Guess I'll be making a trip to Vancouver WA for a "tour of the facility"
And cube theft!
This is so cool, thank you for making a part 2!
Nice job! I made my own puzzle cube a few year ago from Toolsteel hardned to 60HRC. Still good as new :-)
This is a very good flex for a company. That's one ad I wouldn't be mad to watch on YT.
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.
Beautiful performance with the quality and excellent fit for precision parts! Metal machining has come a long way with modern technology!
I saw a video short, and had to come check it out! Awesome!
Великолепно! Респект и уважение!
Прекрасное оборудование. Высокий уровень эксплуатации.
"The tolerance is 1/10 of 1/1000 of an inch." Thank you freedom units.
lmao
Or .0001 of an inch ,most machines shops use decimal.
They were just trying to emphasize how small it was. Normally you would say a 1/10000 of an inch.
At least they're using powers of 10 here.
I guess they'll come to their senses sooner or later.
Aaaany minute now...
1/10 of 1/10 of 1/10 of 1/10 of an inch.
Those tolerances tho 😍 you can’t even tell it’s a separate piece
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.
Thank you for all you do in our community!
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.
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!
Impressive work and technological genius. Hats off
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...
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!
“Hey do we sell these?”
“NO!! AND STOP FUCKING ASKING ME THAT!!”
this is amazing I am so amazed for how hard you work for it😮
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!
Whoever's managing this, good job.
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...
Might be hard to give individual faces the colours - but yeah, that would be amazing
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.
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.
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.
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
I always keep at least a ± 1 thousandth, can't ever imagine getting ±0 at multiple curved angles. Amazing work here!
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.
Thanks for sharing this! 👍
🙂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!
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
..
Stunning piece of machining!
I am a fan of technology watching this makes me so comfortable and relax!
Awesome, thanks for the detail video
Saw these type of block precision in one of BLUM factories in austria.i was so curious on how did they do that.
Wow! That's very interesting! I'm gonna subscribe right now.
i appreciate this ad. very honest that its an ad, while still entertaining and educational
This wasn't ad, this is tutorial. XD
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...
Well, I wish they could but I understand so it’s aight
I would happily pay 100-200$ for one of these things.
@@GRAITOM doubt you will get one for that price.
These are holding 10ths , making a part to the 10th isn't cheap
Yeah, EDM is a slow and precise machine
Aye, let rich people spend their money and auction them. Would be a profitable opportunity for the marketing department for a limited run
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.
no it costs a ton of money to make these
I think pleasure is more important than money 😊@@aperson696
Thank you for this easy DIY tutorial. Now I can make there cubes at home.
The wire cutting process is so beautiful
Okay, so the better question is: WHEN are you going to start selling these?
Can hook you up with one, 1700$
@@kobalov1 if u want that ?
if you emailed them offering a couple grand they might, because it would cost a couple grand.
They would lose a lot of money on every one they sold
If you do start selling them I would buy a bunch. Great job, keep up the great work and God Bless you guys and your families.
Ok give me 10k$ i can make you a few
Lol, it would be at leas few hundred bucks for a set, if not more than 1000$.
🌞⭐⭐⭐⭐⭐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
..
Thanks for the video, I really enjoyed it and it answered a lot of questions that I had.
I never would have imagined that you use a bandsaw to cut through the steel blocks. What is the blade made out of and how often do you need to sharpen/replace it?
Nice moves, wire edm makes great radius and contour sc lathe tools too!
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
Nope. Not worth it.
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.
IMAGINE
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?
Make it out of Iridium.
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!
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! :)
2:22 looks like so much fun! Wish you guys would sell those!
You couldn't afford it.
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.
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.
That's .0001 inches, or 0.0025 mm - insanely small, considering most machining applications only require a tolerance of .005 inches (~0.01 mm).
Surface grinding them in position really sells it 👌
So its a demonstation of your percision. Very nice.
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!
According to a comment on this video, these cubes would cost $1500 each because they're crazy expensive to make.
@@profex.
Tight tolerances like this would cost about 10 grand apiece.
I love how working discharge machine produces smoke and bright light. You can say it's magic and you won't be far off.
This cube is so satisfying to watch
For we non engineers, this explanation helped understand better - Thanks 👍🙏
Even for its small size I legit would spend $20 on this if it was for sell. The quality is incredible.
Not even close to what this costs to make.
Ahmm.... it took 2+ hours to just cut it out minus all the hours planing grinding, the materials used, labor, skill, accessibility to the super duper expensive equipment. I'd say that piece is around 500$ on the low end 1000$ on the high.
According to a comment on this video, these cubes would cost $1500 each because they're crazy expensive to make.
@@MrWiseinheart
This kind of precision commands five-figures, easy.
This cube is not for sale, we made this for demonstration purposes only.
Never say never. I'm hoping the cube will go on sale eventually lol.
Please
*PLEASE*
Sell the cube
_Pretty please?_
:((( give me that cube used for demonstration
Please 🥺 sell some of it
Aww man I'd pay top dollar for something that satisfying
Human ambition to perfection. Awesome.
Now that is precision!!
Put me down for a few! awesome!
Great video of using a Mitsubishi EDM machine from MC Machinery to make really high-tolerance parts.
I didn't think i could see that kind of precision in my life
Awesome cube !. I want one !
satisfying to watch...thats great and amazing tools are always mesmerizing to me...this kind of content..how they do it..and now i see of my two eyes..of that unbelievable idea of human being to create those kind of a hightechnology tools...keep it up 👍👍👍
mad respect for not making this 30 minutes long
I will never ever in my life use this information for anything but man was I entertained
And of course I want one...... Simply amazing..
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.
Bro they would probably cost $1000 dollars (no joke, it takes 4 hours to cut it.)
@@SilenceBot Yea I believe it
US Digital: These puzzle pieces are not for sale.
Me: *THEY SHOULD BE.*
If you guys ever do sell those puzzle squares be sure to make a video about it, I think they are kind of cool
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🤙
Very cool process, I would love one of them cubes.. seems they might be a bit expensive to manufacture though. Thanks for sharing enjoyed the video
Very cool thanks for sharing with us.
Le gana una galleta María jajaja, muy buen trabajo para todo el equipo
Great. Now I want one.
love the brilliance
“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
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
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 ❤
"1/10th of a 1/1000th of an inch." Imperial at its finest.
I like the way you promote!
I understand how the EDM process works, but it still seems like magic to me...
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
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.
Looks great
Engineering precision at it's finest
Amazing and unbelievable.