OUR PROCESS
Voxel has developed pulsed electrochemical machining, or PECM (sometimes called precision electrochemical machining) for its contract manufacturing services; PECM is an advanced machining technology that enables unique geometries, better tolerances, and faster machining times than competing manufacturing technologies.
WHAT IS PULSED ELECTROCHEMICAL MACHINING (PECM)?
Pulsed electrochemical machining, also known as precision electrochemical machining (PECM) is a non-contact, non-thermal advanced material removal process capable of small features, super-finished surfaces, and high repeatability for metallic parts.
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Unlike other material removal technologies such as electrical discharge machining (EDM), Voxel's electrochemical machining is based on the principles of electrolysis. The machining operation involves a tool (the cathode) in the inverse shape of the desired workpiece (the anode).
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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. As PECM can produce parts in parallel with excellent repeatability, it is well-suited to high-volume and/or high-value production.
Step 1
Cathode and anode are
set up and electrolyte is pumped between the
two parts.
Step 2
As the two pieces move together a pulsed DC current is applied to the anode and cathode.
Step 3
The flowing electrolyte removes heat and waste products from the gap.
Step 4
The workpiece is machined into the complimentary shape of the cathode tool.
Step 5
Part is complete with no need for any secondary processing, burr removal,
or polishing.
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
If you have questions about a material not present on this list, please contact us.
UNPARALLELED ACCURACY
Creating precision parts from advanced metal alloys is a growing challenge facing our customers.
PECM is the next generation of electrochemical machining (ECM), permitting novel designs, producing 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 certain energy applications.
No recast layer, no heat-affected zones, no burrs
Ability to machine thin walls and microstructures
High repeatability, no tool wear
3D shape produced in a single step
