P-WIRE vs. Brass Wire: 47% Faster EDM Cutting on Mitsubishi MV2400S
Key Takeaways
- 47% faster than standard brass wire on Mitsubishi MV2400S
- 73 minutes saved per job (227 min → 154 min)
- Zero wire breakage on 60mm thick SKD11 workpiece
- Verified by independent customer testing under identical conditions
What Was the Test Setup?
The customer ran both wires on the same machine, same workpiece, same program, same shift — the only variable was the wire itself.
| Parameter | Value |
|---|---|
| Machine | Mitsubishi MV2400S |
| Wire Diameter | 0.25 mm |
| Workpiece Material | SKD11 (Tool Steel) |
| Workpiece Thickness | 60 mm |
| Cutting Program | Identical for both wires |
| Wire Type A | Standard Brass Wire (CuZn37) |
| Wire Type B | P-WIRE Ultra-HIGH Speed (CuZn35 Reinforced Composite) |
What Were the Results?
| Metric | Standard Brass Wire | P-WIRE | Difference |
|---|---|---|---|
| Total Cutting Time | 227 min | 154 min | −73 min (−32%) |
| Cutting Speed | 100% (baseline) | 147% | +47% faster |
| Wire Breakage | Wire broke during cut | Zero breaks | Improved reliability |
| Surface Finish | Standard | Equal or better | No quality trade-off |
Customer Feedback
The customer was quoted after the test:
"We ran the exact same program, same material, same machine. P-WIRE finished significantly faster than our standard brass wire — and it didn't break once. For our production volume, the time savings translate directly to more parts per shift and lower cost per part." — Production Manager, Precision Mold Shop (Japan)
Why Is P-WIRE Faster Than Standard Brass Wire?
P-WIRE uses a reinforced composite coating over a CuZn35 core. The gamma-phase zinc coating vaporizes at a lower temperature than the brass core, creating a micro-explosion that blasts eroded debris out of the cutting kerf more efficiently. This improved flushing means the next spark hits clean material — not re-cutting already-eroded debris.
Three factors contribute to the speed advantage:
- Better flushing = more spark energy goes into cutting fresh material
- No wire breaks = no downtime for re-threading and re-referencing
- Stable discharge = the machine can maintain maximum feed rate throughout the entire cut
How Much Time Can You Save With P-WIRE?
Use this formula to estimate your own time savings:
Your Current Cut Time × 0.68 = Your Estimated P-WIRE Cut Time
Based on a conservative 32% time reduction. Some customers see up to 47%.
Frequently Asked Questions
Is P-WIRE really faster than brass wire for EDM machining?
Yes. In verified customer tests, P-WIRE delivered 31-47% faster cutting speeds compared to standard brass wire under identical conditions (same machine, same workpiece, same parameters).
Does P-WIRE reduce wire breakage on thick workpieces?
Yes. A customer cutting a 60mm thick SKD11 workpiece reported zero wire breakage with P-WIRE. Standard brass wire broke during the same cut, causing the machine to slow down after re-threading.
Can I use P-WIRE on my machine?
P-WIRE is compatible with all major WEDM brands: Mitsubishi, Sodick, FANUC, CHMER, Makino, and more. Available in 0.20mm, 0.25mm, and 0.30mm diameters.
How can I test P-WIRE on my EDM machine?
JIELINK offers a Performance Trial: purchase one spool at a trial price, run your own comparison test. If you place a follow-up order, the trial spool cost is credited back.
Test P-WIRE on Your Machine — Same Test, Your Numbers
Get a trial spool. Run the same part. See your own before/after comparison. We'll even help you document it as a case study.
Start Your Performance Trial →