Wire electro-discharge machining (WEDM) is considered a non-conventional machining process. It relies on micro erosion on the workpiece via small arcs between the workpiece and a wire. It is well regarded for being a zero-force machining process with the ability to process difficult materials (high toughness, high melting temperature…). WEDM is also able to machine complex geometry or parts that are difficult to handle. To enhance workpiece acceptance, horizontal WEDM can be implemented. It consists of a different machine layout where the wire is in a horizontal position.

Throughout this project, a horizontal WEDM arm was designed and manufactured. A design procedure was established and it was found that the critical design points to be tackled are:

• Possibility to adjust the wire nozzle position precisely.

• Ensuring stiffness of the component.

• Providing adequate fixture possibilities.

Those requirements were implemented in a computer-aided design (CAD) model and the manufacturing considerations were expressed. The project outcome is a close-to-definitive working product. Further work is required to finish the implementation of horizontal WEDM.