In stock, ready to ship and competitively priced, Saturn Industries designs and manufactures both custom and standard EDM tapping electrodes with the end-user in mind; eliminating issues of centering, positioning and burring in the machining process. Only the skilled machinist, experienced with EDM will know all the variables affecting their machining process, but Saturn's unique and innovative electrode design has saved EDM machinists worldwide, countless hours of fabrication time.

So how do they do it? Three design modifications are the key!

• Round Shanks – our round shank design ensures that the electrode is centered in the chuck every time. This, in turn, allows dead center positioning on the workpiece to produce a more accurate thread.
• Timing Flats – The inclusion of a timing flat on the shank of the electrode ensures accurate and consistent lead thread positioning, saving time for the machinist by eliminating the need for manual positioning. This feature provides a significant cost savings benefit.
• Champhered Lead Threads – Yet another superior design standard, Saturn manufactures every tapping electrode with a champhered lead thread, which eliminates burrs and produces a clean lead thread in the workpiece.

Saturn keeps a larges quantity of standard sized orbital and non-orbital tapping electrodes in stock so their customers can realize a substantial cost savings. Many of Saturn's tapping electrodes also come standard with flush holes. A far better alternative to time-consuming manual flushing or messy external flushing methods. built-in flush holes create pressure and facilitate flushing of debris and sludge during the threading process.

Saturn can also custom manufacture tapping electrodes to the customer's specification.

Saturn's custom production capabilities include:

• Saturn can produce electrodes using practically any combination of special pitch diameters, pitches and thread forms.
• For mold makers, Saturn can produce special taps that take shrink factor into consideration.
• Saturn can mount threading electrodes on 20MM 3R shanks.

Standard sizes:

• English - from 0-80 (available only from Saturn) up to 1-14
• Metric - from M1.6x.35 up to M20x2.5

Available electrode materials:

• Copper Tungsten
• Brass
• Copper
• POCO EDM-3 Graphite
• POCO EDM C-3 Copper Impregnated Graphite

• Since 1959, Saturn has pioneered new technologies to produce the highest quality electrodes, inspecting each electrode on a pitch diameter to a tolerance of +0/-002. Saturn electrodes are straighter, have superior pitch diameter control and have better thread form, which means that when you buy a Saturn electrode, you can be sure that you've purchased the finest electrode available.

Contact one of the experts at Saturn today for answers to your EDM tapping needs!

Metal EDM Electrodes

Producing metal EDM electrodes is a Saturn specialty. Their unmatched knowledge and experience in working with metals has made them the industry's leading manufacturer of metal electrodes for EDM.

Saturn offers a range of metal EDM electrodes in a variety of materials, including copper, copper tungsten, tellurium copper, brass, tungsten carbide, pure tungsten and many special alloys.

The world's smallest Tungsten Carbide EDM rod and tube electrode diameters are available from Saturn Industries! With solid rod sizes as small as .002 diameter and tube starting at .0043. Saturn has been meeting the needs of specialized applications for the Aerospace, Automotive and Medical industries (just to name a few) where tight tolerances are absolutely essential.

Saturn's Tungsten Carbide Electrodes come in three different configurations; solid rod, tube and roto tubes:

• Solid Rod - available down to .002 with diameter tolerances as tight as -.00015/-.0002.
• Tubes - available down to .0043 OD with a through hole for applications requiring a center hole flushing capability. Tolerances are as tight as -.0003/-.0001.
• Roto Tubes - available down to .050 OD with outside diameter tolerances as tight as +/-.0002. These tubes include offset flush holes to avoid spikes at the bottom of "blind" holes.

Typical Applications include:

• Spray holes in fuel injector tips for the automotive industry
• Small hole aerospace applications
• EDM holes in needle tips for medical applications

Saturn Industries has been providing small hole EDM drilling solutions for over 50 years with standard sizes competitively priced. 80% of their orders are shipped the same day.

Email or call Saturn Industries today and speak to one of their sales engineers about your application needs!

Graphite EDM Electrodes

Graphite electrodes are by far the most popular EDM electrodes used in the United States. With their extensive inventory of graphite materials, they can quickly produce electrodes from any grade required.

Saturn graphite electrodes are carefully crafted to meet highly specific parameters. These include level of detail, material strength, wear resistance, processing speed, surface finish and cost.

• VITALITY™ - BIO-ENRICHED EDM FLUID
  VITALITY™ is the world's first "Bio-Enriched Synthetic" Dielectric Fluid. Formulated to support the most demanding dielectric applications while simultaneously maximizing protection for both machine operators and the environment, VITALITY™ is a revolutionary dielectric fluid. A Bio-Enriched Fluid is one that fundamentally incorporates pharmaceutical & health-promoting components. VITALITY™ is manufactured with only precisely specified basestock distillates, homogenated in a super blend process while infusing a proprietary anti-oxidant package.
  
  

• EDM 244™ - DI-ELECTRIC FLUID
  Typical of the Commonwealth Oil attitude, we set out to formulate the best Electric Discharge Machining Fluid possible, using independent Consultants.
  
  

• EDM SUPER SUPREME™ - HD SYNTHETIC DI-ELECTRIC FLUID
  EDM-244 TM Electric Discharge Machining Fluid has always been recognized as the flagship of all EDM fluids, while establishing new benchmarks for product safety and performance. Faster machines, shorter delivery times, tighter tolerances, environmental concerns, dry skin and dermatitis demand a revolution in EDM Fluid. The laboratory of Commonwealth Oil is proud to announce EDM Super Supreme™. We have established performance and safety levels previously unheard of in the EDM industry.
  
  

• EDM SUPREME T™ TRANSOR APPROVED SYNTHETIC DI-ELECTRIC FLUID
  The laboratory of Commonwealth Oil is proud to announce EDM Supreme T™. EDM Supreme T™ has been specifically developed to function in very demanding "Ram-Type" operations where very tight filtration requirements must be met by a Transor Filtration System. EDM Supreme T™ will also work equally well in other systems utilizing diatomaceous earth, pleated filter paper or bag filter vessels. As Commonwealth Oil customers have come to expect, we continue to establish performance and safety levels previously unheard of in the EDM industry.
  
  

• EDM 259T - TRANSOR APPROVED DI-ELECTRIC FLUID
  Typical of the Commonwealth Oil attitude, we set out to formulate the best Electric Discharge Machining Fluid possible, using independent consultants.
  
  

• EDM V - WIRE EDM CORROSION INHIBITOR
  Typical of the Commonwealth attitude, we decided it was time the Wire EDM Industry was introduced to a truly World Class corrosion inhibitor.
  
  

• EDM FLUSHING FLUID™ (FOR RAM TYPE MACHINES)
  EDM FLUSHING FLUID™ is a food grade quality oil designed to serve as a flushing fluid for "die-sinkers". EDM Flushing Fluid™ should be used only after the machine has been thoroughly cleaned, and before refilling with fresh dielectric fluid.
  
  

• MICRO-FINE 49™ - DI-ELECTRIC FLUID
  MICRO-FINE 49™ Di-electric EDM Fluid has been specifically formulated to hold fine particulate in suspension for extended periods of time for high speed EDM Machines requiring these characteristics.
  
  

• SPARKMASTER - DI-ELECTRIC FLUID
  SparkMaster is a special fluid developed specifically for Electrical Discharge Machines of all power sizes. SparkMaster works very well when machining your graphite electrodes.
  
  

• EDM 185 - DI-ELECTRIC FLUID
  EDM 185 is a special fluid, developed specifically by Commonwealth Oil for Electrical Discharge Machines utilized to produce very fine and intricate cuts and profiles. EDM 185 also works very well when machining your graphite electrodes.
  

Sinker EDM (a.k.a Vertical, Plunge, Conventional, or Ram):
This was the original EDM process, in which a "male" electrode "sinks" into a workpiece producing a "female" cavity which is an exact, inverse replica of the electrode. Initially used to produce die openings for stamping dies, it was later used to produce intricate punches, and production parts. These are single-axis machines, usually vertical, which cut in one direction. Twenty years ago, when someone mentioned EDM everyone thought of Sinker EDM.

Tolerance

Sinker EDM is capable of holding very close tolerances, down to +/-.0001 inch. In addition, it is capable of very good geometric accuracies, such as flatness, parallelism, and squareness, due to the absence of any forces between the electrode and the workpiece, which would cause deflection in conventional machining.

Inaccessible Features
Inaccessible features, such as cross connections between bores, or features cut sideways at the bottom of deep, blind cavities, can be readily produced without having to enter externally and plugging afterwards. The electrode can be mounted on an arbor, which is then manipulated into position inside the workpiece, and then the feature can be cut in any direction. In especially tight quarters, a through-feature can be EDM'ed from both directions to meet in the middle. In many cases, EDM is the only way these types of features can be produced.