CAM solution for wire EDM

    Use OPTICAM to create NC programs for wire EDM efficiently and flexibly, regardless of whether this involves simple 2-axis movements or complex 4-axis movements. OPEN MIND offers the proven OPTICAM wire-cutting module within its hyperCAD®-S CAD software.

    Wire spark Erosion (EDM) | CAM software

    Wire EDM works according to the principle of spark erosion and is also referred to as spark erosion cutting or erosion cutting, wire cutting or wire erosion. Electrothermal separation processes are available as an alternative to cutting manufacturing processes when a low mechanical strain is required to manufacture highly complex geometries with the smallest corner radiuses and the best possible surface quality. High-precision CNC machines move the tool wire (cathode) with extreme positional accuracy and cut a programmed contour in the workpiece (anode) using spark erosion.

    The proven solution for wire EDM

    OPTICAM CAM software has been used to operate wire electrical discharge machines efficiently and safely. OPTICAM has extensive functions and uses the technology databases from all major manufacturers and up-to-date postprocessors to solve any problem that may be encountered in wire EDM.

    OPEN MIND provides the fully integrated OPTICAM wire EDM solution in hyperCAD®-S. As a modern ‘CAD for CAM’ environment, the hyperCAD®-S CAD software additionally speeds up programming work. It is possible to create milling, mill turning and wire EDM programs on one and the same model. All the user needs to do is switch between the OPTICAM wire-cutting module and hyperMILL® CAM software.
    The OPTICAM solution meets all requirements with regard to integration, reliability and user friendliness and is therefore certified for hyperCAD®-S.

    Wire cutting

    CAD Integration: OPTICAM in hyperCAD®-S
    PDF | 2.3 MB

    Wire cutting: CAD Integration | Brochure

    Features of wire EDM

    Feature recognition

    Feature recognition | EDM | Wire spark erosion

    Automatically to the NC program: During component analysis, wireable geometries are reliably recognised as features. Faces or edges can also be chosen manually for the wire EDM of only specific areas or for the creation of user-defined features. The optimal machining strategy is identified for each feature and immediately defined using extensive technology databases.

    • Automatic feature generation
    • Use of feature information
    • Undercut control
    • Maximum conicity control


    The toolpaths can be reliably checked in a 3D simulation. Collision-checked machine and removal simulation makes it possible to closely monitor the workspace and provides a high degree of safety. The path offsetting, clamps and machine heads are displayed. The cutting time can be quickly and easily calculated for each wire EDM operation. This ensures that machining times can be planned perfectly.

    Technology databases

    The OPTICAM module is continuously adapted to the latest functions of wire electrical discharge machines. Thanks to its extensive range of functions, the module is the market leader in the field of wire cutting and is recommended by many renowned machine manufacturers. The technology databases are always up to date as they come directly from the machine manufacturer.


    The postprocessors are constantly being upgraded by the OPTICAM manufacturer, Camtek, and always in close cooperation with the machine manufacturers. This ensures that the postprocessors are always up-to-date and reliable.

    Optimal strategies

    The right strategies for every feature: The optimal machining strategies are identified and immediately defined using extensive technology databases based on their suitability for the machining job. Faces or edges can also be chosen manually for the wire EDM of only specific areas or for the creation of user-defined features. All cuts are shown in the cuts dialog. Toolpaths can be changed afterwards.

    Wire EDM strategies:

    • Cylindrical machining
    • Constant and variable taper, also on cylindrical components
    • Ruled face machining with automatic synchronisation
    • Inclined machining
    • Automatic threading and cutting of wires
    • Diagonal threading
    • Automatic positioning
    • Automatic clustering of identical geometries
    • Multi-part programming
    • Variable reference plane height

    Strategies for efficient and reliable wire EDM

    • Supervised and unsupervised day and night operation
    • Punch strategies
    • Reverse cutting
    • Automatic cutting off of slugs
    • User-defined strategies can be saved as templates


    Pocketing | EDM | Wire spark erosion

    Machine downtimes and manual intervention all cost money. The solution to this problem is efficient pocketing without slugs using the following strategies: cylindrical and conical pocketing, 4-axis ruled face pocketing*, partial pocketing of geometry sections*

    *Module is optionally available

    Collar machining

    Collar machining | EDM | Wire spark erosion

    Projection at a freely definable angle makes it possible to machine variable reference plane heights. This allows a constant, cylindrical collar with a uniform height to be created on the workpiece.

    Ruled face pocketing

    Ruled face pocketing | EDM | Wire spark erosion

    Makes it possible to machine ruled faces without slugs. This significantly reduces programming work and allows unsupervised machining.

    Partial pocketing

    Allows conventional roughing and pocketing to be combined.

    Corner relief

    Allows targeted control of the toolpath in sharp interior corners: Five types of corner relief are available without having to spend time changing the model.

    Events and segments

    Key comments or useful machine instructions can be quickly and easily inserted using event points. Machining operations are divided into individual segments. This way, it is possible to set the number of cuts, offset values, lead on and lead off technologies or partial pocketing separately.

    Lead on/lead off

    Straight, at an angle, arc-shaped and meander-shaped with the option to overrun the cutting contour. Lead on and lead off technologies can be programmed.

    Start holes and tags

    OPTICAM always calculates the optimal start holes and tags, regardless of whether this is performed fully automatically and optimised, predefined on the basis of the design or selected manually. Any predefined start hole geometries are taken into account. The type, position and number of tags can be defined automatically or manually. Triangular and multiple tags can also be created with multiple start holes.


    • Simple and fast programming of wire electrical discharge machines
    • Integrated in a powerful CAD system that allows 3D data to be easily prepared
    • Extensive strategies for wire electrical discharge machines with two to four axes
    • User-defined strategies can be saved as templates
    • Automatic feature generation
    • Use of feature information