In high-tech industries, at companies such as ASML, Zeiss and Thermo Fisher, even a single copper or zinc atom can result in a part being rejected. Mitsubishi Electric has therefore developed Zerocon, an integrated solution that combines machine, software and wire technology in one validated production platform for contamination-free wire EDM.
In conventional configurations, wire EDM inevitably causes micro-contamination originating from the wire material. For general applications, this is not a major limitation, but for components used in high-tech sectors, material purity and reproducible quality are essential requirements. As a result, demand is increasing rapidly for processes that can guarantee both accuracy and extremely high purity. Mitsubishi Electric positions Zerocon as its response to this requirement, with an emphasis on a controlled wire EDM process in which every process step is aligned to enable contamination-free machining.
Full process control
To achieve this level of control, Zerocon has been designed as a complete ecosystem in which several technological components jointly define the process. The ecosystem consists of a dedicated machine series, a copper-free wire and a Zerocon technology database with validated parameters. It also includes certification and commissioning based on a fixed reference part, as well as extensive training, service and process support. To meet the extremely stringent requirements for contamination by copper, gold, silver and zinc, as set out in ASML GSA standards or similar specifications, the entire wire EDM process must be configured accordingly. With Zerocon, Mitsubishi has developed a complete and controlled process that can meet these extreme cleanliness requirements without any post-treatment.
Copper-free wire
Within this ecosystem, Mitsubishi’s copper-free ZETA-CON wire is a crucial component. This wire prevents elements from the wire from diffusing into the workpiece, which is a common cause of rejection in high-tech industries. It provides full material purity and high process stability, enabling reproducible results. Its design ensures high surface quality and reduces the need for secondary finishing. In addition, the wire is up to 80% more cost-effective than molybdenum alternatives. The wire has been specifically matched to the P12 and P24 wire EDM machines, creating a uniform and controlled EDM process.
Specialized wire EDM machines
The P12 and P24 EDM machines are derived from Mitsubishi’s MP platform, but have been adapted for production environments where contamination control is essential. With axis travels of 400 mm x 300 mm x 220 mm (XxYxZ), the P12 is suitable for workpieces weighing up to 500 kg, while the larger P24, with axis travels of 600 mm x 400 mm x 310 mm (XxYxZ), can handle workpieces weighing up to 1,500 kg. To achieve exceptionally high accuracy, the wire EDM machines are equipped with Mitsubishi’s Tubular Shaft Drive. This innovative drive guarantees extremely high positioning accuracy and repeatability of +/- 1 µm, with minimal heat generation and maintenance. Thanks to a dedicated wire annealing system, the AT Intelligent Auto Threading system ensures stable wire feeding, even without a water jet or when threading directly in the spark gap. With Maisart AI, EDM parameters are optimized within the Zerocon framework.
Validated database
As a further step in process control, Mitsubishi Electric supports users with the Zerocon database. This provides pre-validated settings for materials such as titanium, Inconel and Stavax. The parameters have been developed in combination with ZETA-CON wire and are aligned with common high-tech standards. This gives users direct access to cutting conditions that prevent contamination and ensure accurate geometry. Mitsubishi has carried out practical tests on a Stavax workpiece, achieving surface roughness values of up to Ra ≤ 0.35 micrometres, contour deviations within ±0.002 mm and stable dimensional tolerances for workpiece heights of up to 70 mm. Thanks to the validated settings, customers can achieve extremely good results immediately, without a trial-and-error phase and without wasting material or time.
Support and certification
In addition to machine and process parameters, Zerocon also includes a comprehensive support programme. During installation, the system is validated using a reference part, and the user receives focused training and process guidance. Remote service, periodic inspections, warranty and options for extended maintenance create a predictable operating environment. This helps keep the process stable and consistent, even under demanding production conditions.
