Specialist EDM services provider rewires its strategy

Subcontract EDM services provider, EDM Solutions (Stroud) Ltd, drives its success through smart investment strategies and a willingness to challenge the norm. This approach is clearly evident in its recent move to Excetek EDM machines supplied by Warwick Machine Tools, with results already making a marked impression across this progressive manufacturing business.

EDM Solutions’ approach is rooted in a journey that dates back more than two decades. In 2004, Mike Smith launched EDM Solutions as a one-man-band with two ageing machines at the rear of a car repair garage. Fast forward to today and the Gloucestershire-based subcontractor has built a reputation as a go-to specialist for wire, die-sink and fast-hole drilling EDM.

Progress has been far from accidental. It’s come from a concentrated focus on customer service, astute machine selection and the ability to adapt when markets shift.

“We’ve grown consistently from the outset,” Mike comments. “We now have 12 high-spec CNC EDM machines, a growing workforce, and a strong and expanding customer base in sectors such as oil and gas, medical, and aerospace.”

A strategic shift in thinking
For many years, EDM Solutions relied on the same EDM machine brand. But the time was right for a change.

“I wanted to move towards newer technology with higher capability, backed by proven support,” reveals Mike. “These were the key factors in my decision.”

It marked a turning point. EDM Solutions began reassessing what really mattered: performance, support and cost. The introduction of two Excetek machines supplied by Warwick Machine Tools, namely an ED400C CNC spark erosion (die-sink) machine and a HD30Z hole-drill EDM, provided the proof points.

“I was so pleased with those machines that when it came to specifying another, I didn’t hesitate.”

The arrival of a giant
The latest investment came in the form of a large-capacity wire EDM: an Excetek V850G Plus, installed in January 2026. And it’s no small step up. With an 800 x 500 mm table, 410 mm maximum cutting thickness and 1,050-litre tank, the V850G Plus is a major addition to the shop floor.

Mike describes what prompted him to invest in the company’s first Excetek wire EDM: “We’d been running a waterjet cutter for about 10 years. However, when we lost a big customer for that type of work, I made the decision to end our waterjet services and use the space for a large wire EDM instead, a machine that I knew would really add to our capabilities.” It’s a move that’s already delivering returns.

“When processing thicker materials from 50 to 400 mm, EDM delivers outstanding edge quality and cost efficiency, making it the preferred choice for many jobs that previously went on the waterjet.”

Performance that backs up the decision
Switching suppliers is never a small call. But for EDM Solutions, the numbers made the decision easier.

“When I was quoted for a new wire EDM, the difference between Warwick Machine Tools and our previous machine supplier was unbelievable. And because we were already running two Excetek machines, I knew the performance was there.”

He adds: “Our confidence was reinforced during testing. We cut a selection of trial parts one of our existing wire EDMs and compared them with components we took to cut on a V850G Plus at Warwick’s showroom. The Excetek was faster. Sure enough, the technology is newer, but it gave us even more assurance.”

And yet speed is only part of the story. Running costs are where additional long-term gains manifest. According to Mike, he can run the new Excetek V850G Plus with a standard brass-coated wire (bedra betterbrass) that’s almost half the price of the premium wire used on the company’s existing wire EDMs.

“For example, if I feed 10 reels of wire through the V850G Plus [5kg each reel], it equates to about £750 of savings. Over the course of a year, you can imagine how it adds up. And there’s no compromise in speed.”

Unmanned running, real impact
One of the stand-out features of the V850G Plus is its automatic wire threading (AWT) system, which has helped transform daily operations at EDM Solutions. Thanks to the AWT, Mike and his team can now run unmanned overnight with complete confidence.

“Last week, for example, we were running lights-out 14 hours a night, every night. That kind of capability has an enormous impact on a subcontractor built around responsiveness and short lead times. It also releases technicians during the day to add value in other areas while we quietly build output overnight.”

Although performance and cost were key drivers behind the switch of EDM machine supplier, support proved just as important, as Mike sets out: “In terms of Warwick Machine Tools, the support’s been exceptionally good. No complaints at all. A strong service response matters, especially for a small business where downtime can prove extremely costly.”

Driven by investment
Today, EDM Solutions remains disciplined in how it grows. Mike is clear: “We don’t overstretch ourselves. If we’ve got the money, we invest. We’ll buy a machine outright and keep overheads low.”

Recent investments underline that philosophy. The company has bought three new Excetek EDM machines from Warwick Machine Tools in the past 18 months. Such a forward-thinking approach is helping EDM Solutions continue its impressive trajectory, with year-on-year gains in turnover and customer numbers fuelling high levels of optimism for the future.

The addition of the Excetek V850G Plus is clearly playing a key role in momentum at EDM Solutions, bringing new capacity, improved efficiency and lower operating costs. More than that, it represents a new way of thinking, one focused on making decisions based on real-world performance and economics in support of the company’s growth strategy.