Customer Background｜Optical Protection Industry Leader in Asia

The project partner is a leading manufacturer in the Asian optical protection sector, specializing in:

• Optical-grade goggle molds
• Laser (IR) and welding protective lenses
• High-transparency spherical, cylindrical, and aspherical mold designs

This manufacturer maintains extremely high standards for EDM surface roughness, curved surface uniformity, and machining efficiency, particularly for molds used in optical and protective applications.

Customer Challenges｜Non-Uniform Large-Area Machining, Carbon Buildup, and Excessive Machining Time

The project involved machining a goggle mold curved surface exceeding 10,000 mm², presenting multiple challenges:

• Difficulty achieving surface roughness below VDI 18
• Inconsistent texture across large curved areas with localized carbon buildup
• Poor debris evacuation in deep cavities (-70 mm), resulting in extended machining times
• High acquisition cost and long ROI cycles associated with Japanese and European EDM equipment

The customer sought a stable and cost-effective EDM solution capable of improving both surface quality and production efficiency.

Machining Task Specifications

NEUAR 3-Axis High-Precision Automated Sinker EDM Solution

To overcome the typical challenges of large-area curved surface machining—such as uneven texture, carbon buildup, poor debris evacuation, and long machining cycles—the NEUAR 3-Axis High-Precision Automated Sinker EDM, combined with the AE II high-speed control system, integrates multiple core technologies to significantly enhance both efficiency and surface quality.

The AE II system improves discharge energy control precision and stability through:

• High-speed pulse response, ensuring real-time and stable energy output
• Precise energy control, delivering consistent discharge points across the surface
• Arc suppression logic, effectively preventing burn marks and carbon buildup
• Wide-area energy equalization algorithms, ensuring uniform texture and consistent roughness
• With AE II, curved surfaces exceeding 10,000 mm² maintain consistent surface appearance, avoiding localized overheating or color variation

The AE II control system directly addresses common issues in large-area EDM machining, such as localized overburn and uneven surface coloration. This technology is the key enabler for consistently achieving VDI 15 / Ra 0.5 in this application.

Wide Area Pulse Distribution – Consistent Surface Quality Across Large Curves

This technology enables:

• Dispersion of localized energy concentration
• Uniform surface roughness across the entire area
• Prevention of excessive texture contrast
• Stable and repeatable EDM patterns suitable for optical-grade curved molds

With localized energy distribution strategies, large-area curved surfaces maintain consistent EDM textures, eliminating uneven brightness and pattern discontinuities commonly seen with conventional EDM machines.With our localized energy distribution strategy, large-area curved surfaces maintain consistent EDM textures, eliminating the uneven brightness and pattern discontinuities commonly seen on optical-grade curved molds with conventional EDM machines.

Arc Suppression – Reduced Carbon Buildup and Enhanced Surface Consistency

The arc suppression function effectively:

• Minimized carbon buildup
• Prevention of localized burning
• Clean and consistent surface quality
• Final curved surfaces meeting VDI 15 / Ra 0.5 without localized defects

By integrating our 3-axis high-precision automated EDM machine with the AE II control system, we successfully tackled challenges such as uneven surface patterns on large-area curved molds, carbon buildup, and poor debris removal in deep cavities. The complete surface machining was achieved in just 8.5 hours, meeting the demanding requirements of optical-grade goggles molds for both high uniformity and exceptional efficiency.

Key Machine Performance Highlights

• Uniform curved surface finish achieving VDI 15 (Ra 0.5 μm) across the entire area
• Zero carbon buildup and zero burn marks
• Stable deep cavity machining with smooth debris evacuation
• Total machining time of only 8.5 hours
• Approximately 30% efficiency improvement compared to the customer’s previous imported EDM equipment
• Significant reduction in mold processing cost and equipment investment risk
• The AE II control system is the decisive technology enabling these results

Applicable Industries

• Optical goggle mold manufacturing
• PC / PMMA / ABS transparent component molds
• Protective face shield molds
• Large-area curved surface EDM machining
• High-difficulty deep cavity EDM applications

By integrating NEUAR’s 3-axis high-precision automated Sinker EDM machine with the AE II control system, large-area EDM machining can achieve high uniformity, low surface roughness, and exceptional stability—especially in optical and precision mold applications. This solution not only improves surface quality but also significantly increases machining efficiency, reduces process risk, and lowers overall manufacturing costs. If your products involve large curved surfaces, deep cavity structures, or high-precision surface requirements, NEUAR can help you identify the most effective EDM solution.

Our Professional Services Include

• Large-area Sinker EDM machining services
• AE II control system parameter optimization
• Deep cavity machining strategy tuning and debris evacuation improvement
• Equipment integration, training, and application support
• Surface roughness optimization and texture uniformity solutions

If your products involve large curved surfaces, deep cavity structures, or high-precision surface requirements, NEUAR can help identify the most effective EDM solution. Contact us today for tailored technical support and machining evaluation services.