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 "title": "Electrochemical discharge machining",
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 "excerpt": "Electrochemical discharge machining (ECDM), also known as spark assisted chemical engraving (SACE), is a micromachining process that machines nonconductive materials like glass, quartz, and ceramics for MEMS devices.",
 "snippet": "Electrochemical discharge machining (ECDM), also known as spark assisted chemical engraving (SACE), is a micromachining process that machines nonconductive materials like glass, quartz, and ceramics for MEMS devices.",
 "node": "technology.engineering.manufacturing.processes.machining-and-machine-tools",
 "markdown": "# Electrochemical discharge machining\n\nElectrochemical discharge machining (ECDM) is a nontraditional micromachining process that removes material by electrical discharges across a gas film formed in an electrolyte, and it is used to machine electrically nonconductive hard materials such as glass, quartz, ceramics, and silicon wafers for MEMS and lab-on-a-chip devices. The process is also published under the names spark assisted chemical engraving (SACE), electro chemical spark machining (ECSM), and, for electrically conducting workpieces, electrochemical arc machining (ECAM).<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S1388248103000183)</sup><sup> • </sup><sup>[2](https://repository.tudelft.nl/file/File_e50536c1-aff5-4b72-a6a7-977f116447e0?preview=1)</sup>\n\n| Key fact | Value |\n|---|---|\n| Machining voltage | 25–40 V applied between tool and counter electrode, typically in 30% NaOH<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S1388248103000183)</sup> |\n| Critical voltage for discharge onset | Around 30 V in early reviews; approximately 25 V with a critical current around 1 A in later experimental reviews<sup>[3](https://www.sciencedirect.com/science/article/abs/pii/S0890695504002974)</sup><sup> • </sup><sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> |\n| Discharge temperature | 800–10,000 K depending on electrolyte and concentration<sup>[5](https://www.ias.ac.in/article/fulltext/sadh/022/03/0435-0447)</sup> |\n| Material removal zone | Workpiece must lie within roughly 25 µm of the tool electrode (about 20 µm in later reviews)<sup>[3](https://www.sciencedirect.com/science/article/abs/pii/S0890695504002974)</sup><sup> • </sup><sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> |\n| Material removal rate | Combined MRR can be 5–50 times that of EDM and ECM, with decreased tool wear<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> |\n| Minimum feature size in glass | About 25 µm reported as a limit set by gas film thickness in one study<sup>[6](https://repository.tudelft.nl/file/File_a03f6bcc-9f96-4d1c-898b-d44a7c1f803b?preview=1)</sup>, though etched microholes about 6 µm in diameter are separately reported; the figures are not directly comparable<sup>[2](https://repository.tudelft.nl/file/File_e50536c1-aff5-4b72-a6a7-977f116447e0?preview=1)</sup> |\n| Typical products | Micro holes, micro channels, and through-holes in borosilicate glass for fluidic interconnection |\n\n## How it works\n\nThe tool electrode and workpiece are immersed in an electrolyte. As voltage rises, electrochemical reactions generate hydrogen bubbles and electrolyte evaporation generates vapor bubbles; these accumulate into a gas film that isolates the tool electrode from the electrolyte.<sup>[7](https://www.mdpi.com/2072-666X/14/5/1079)</sup> Above the critical voltage the film breaks down and discharge occurs between the tool and the electrolyte. The electric field across the film is typically \\( 10^{6} \\)–\\( 10^{8} \\) V/m,<sup>[3](https://www.sciencedirect.com/science/article/abs/pii/S0890695504002974)</sup> with measurements of order \\( 10^{7} \\) V/m in high-speed imaging experiments.<sup>[8](https://mdpi-res.com/d_attachment/micromachines/micromachines-14-00367/article_deploy/micromachines-14-00367-v2.pdf?version=1676465621)</sup>\n\nSparking is a switching action, not gas breakdown. In the theoretical model of Indrajit Basak and Amitabha Ghosh, at critical bubble coverage the hemispherical bubbles leave narrow conducting bridges; their high current density causes instant boiling that blows the bridge and generates a spark, which is why sparking occurs below the Paschen breakdown voltage.<sup>[9](https://doi.org/10.1016/0924-0136%2895%2902202-3)</sup> Measured and estimated discharge temperatures span 800–10,000 K.<sup>[5](https://www.ias.ac.in/article/fulltext/sadh/022/03/0435-0447)</sup> Both sparks and arcs occur: arcs carry stable current over tens of microseconds and release \\( 2.0 \\times 10^{-4} \\)–\\( 7.2 \\times 10^{-4} \\) J at 40 V, while sparks release \\( 1.76 \\times 10^{-5} \\)–\\( 1.2 \\times 10^{-4} \\) J.<sup>[8](https://mdpi-res.com/d_attachment/micromachines/micromachines-14-00367/article_deploy/micromachines-14-00367-v2.pdf?version=1676465621)</sup> Material removal is thermal, by melting and vaporization, with partial chemical etching; the workpiece need not be electrically conducting because it is placed within the discharge range of the tool tip.<sup>[5](https://www.ias.ac.in/article/fulltext/sadh/022/03/0435-0447)</sup><sup> • </sup><sup>[10](https://publications.waset.org/8540.pdf)</sup>\n\n## How it is done\n\nThe practitioner dips a cathodic tool electrode 2–3 mm into NaOH or KOH electrolyte and places a much larger counter electrode (anode) 25–50 mm away, with roughly a hundredfold larger surface.<sup>[3](https://www.sciencedirect.com/science/article/abs/pii/S0890695504002974)</sup><sup> • </sup><sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> A constant 25–40 V DC or pulsed potential is applied, commonly in 30% NaOH for glass.<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S1388248103000183)</sup> Current–voltage plots show five regimes, which locate the sparking domain for given electrolyte concentration and temperature.<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S1388248103000183)</sup><sup> • </sup><sup>[7](https://www.mdpi.com/2072-666X/14/5/1079)</sup> Sparking begins when tool current exceeds about 1 A and voltage exceeds the critical value; with a DC pulse supply the critical voltage is often reached in the eighth second.<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup><sup> • </sup><sup>[7](https://www.mdpi.com/2072-666X/14/5/1079)</sup> Tool geometry and material matter: tungsten carbide gives the smallest holes and least wear, and a 150 µm spherical tool machines a 500 µm deep through-hole 83% faster with 65% smaller entrance diameter than a 100 µm cylindrical tool.<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> Adding surfactants lowers the critical voltage from 20 V to 15 V.<sup>[6](https://repository.tudelft.nl/file/File_a03f6bcc-9f96-4d1c-898b-d44a7c1f803b?preview=1)</sup>\n\n## Origin\n\nA theoretical model of spark generation, the switching mechanism above, was published by Indrajit Basak and Amitabha Ghosh in the Journal of Materials Processing Technology in 1996.<sup>[9](https://doi.org/10.1016/0924-0136%2895%2902202-3)</sup> Ghosh's 1997 Sadhana paper, \"Electrochemical discharge machining: Principle and possibilities,\" carries the ECDM name.<sup>[11](https://doi.org/10.1007/bf02744482)</sup> The name micro electrochemical discharge machining (µ-ECDM) appears in a 1998 paper in the International Journal of Electrical Machining.<sup>[12](https://doi.org/10.2526/ijem.3.65)</sup> The electrochemistry of the process was analyzed by V. Fascio, R. Wüthrich, and H. Bleuler in Electrochimica Acta in 2004,<sup>[13](https://doi.org/10.1016/j.electacta.2003.12.062)</sup> and the physical principles and miniaturization of SACE were treated by R. Wüthrich and colleagues in the Journal of Micromechanics and Microengineering in 2005.<sup>[14](https://doi.org/10.1088/0960-1317/15/10/s03)</sup> Tool wear and thermal expansion during SACE were studied by Jana D. Abou Ziki and Rolf Wüthrich in 2011.<sup>[15](https://doi.org/10.1007/s00170-011-3731-6)</sup> Reviews note that the technology remained an academic application for almost 40 years after its first mention in the literature,<sup>[3](https://www.sciencedirect.com/science/article/abs/pii/S0890695504002974)</sup> and that published reviews disagree on who coined the SACE name and on when electrochemical discharges were first observed.<sup>[3](https://www.sciencedirect.com/science/article/abs/pii/S0890695504002974)</sup><sup> • </sup><sup>[16](https://journals.sagepub.com/doi/10.1177/0954405418798865)</sup>\n\n## Variants\n\nFor conducting workpieces the same process is termed electrochemical arc machining; for nonconductors it is ECDM, with SACE and spark assisted etching proposed as alternative names.<sup>[1](https://www.sciencedirect.com/science/article/abs/pii/S1388248103000183)</sup> In wire electrochemical discharge micro-machining (WECDMM), a wire tool with a NaNO3–glycol electrolyte removes the recast layer on metal micro parts: when the machining gap is at or below the discharge gap, discharge dominates, and beyond it electrochemical reaction removes recast from slit sidewalls.<sup>[17](https://www.mdpi.com/2072-666X/14/8/1505)</sup> Anodic-polarity ECDM produces spherical cavity microstructures in glass.<sup>[18](https://iopscience.iop.org/article/10.1088/0960-1317/17/2/028)</sup> Hybrid variants include ultrasonic-assisted rotary drilling,<sup>[19](https://www.nature.com/articles/s41598-025-92574-9)</sup> nitrogen gas-assisted ECDµM,<sup>[20](http://www.nature.com/articles/s41598-026-36060-w.pdf)</sup> abrasive-assisted rotary mode ECDM,<sup>[21](https://www.tandfonline.com/doi/full/10.1080/10426914.2026.2632598)</sup> and side insulation, pulsed voltage, and electrolyte ultrasonication to concentrate sparking at the tip and improve flushing.<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup>\n\n## Applications\n\nECDM produces micro holes, micro channels, and through-holes in nonconductive materials for lab-on-a-chip and MEMS devices. Rapid, reproducible through-holes have been machined in 500 µm thick and fragile 180 µm thin borosilicate glass for fluidic interconnection.<sup>[18](https://iopscience.iop.org/article/10.1088/0960-1317/17/2/028)</sup> A hole is typically drilled in about 30 s.<sup>[2](https://repository.tudelft.nl/file/File_e50536c1-aff5-4b72-a6a7-977f116447e0?preview=1)</sup> With series inductance giving a smooth DC discharge condition, quartz has been drilled at 0.3 mm/min to depths of 3 mm or more.<sup>[5](https://www.ias.ac.in/article/fulltext/sadh/022/03/0435-0447)</sup> Reviews report that patterns smaller than about 25 µm cannot be produced in glass because the gas film thickness sets the limit,<sup>[6](https://repository.tudelft.nl/file/File_a03f6bcc-9f96-4d1c-898b-d44a7c1f803b?preview=1)</sup> while an early report describes etched microholes about 6 µm in diameter; these figures have not been reconciled in published comparisons.<sup>[2](https://repository.tudelft.nl/file/File_e50536c1-aff5-4b72-a6a7-977f116447e0?preview=1)</sup> A sheet tool electrode increased machining depth by 42.9% and efficiency by 51.1% and produced a hole 2520 µm deep with 148 µm entrance overcut.<sup>[22](https://link.springer.com/article/10.1007/s12206-022-1012-y)</sup> Micro-channeling with automated spring feeding reached 1.35 mm depth in glass, with applied voltage and duty ratio dominating MRR, overcut, heat-affected zone, and surface roughness.<sup>[23](https://journal.ump.edu.my/jmes/article/view/569)</sup>\n\n## Limitations and alternatives\n\nAn unstable gas film produces fluctuating sparks and nonrepeatable machining.<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> Material removal drops significantly beyond 300 µm depth, where the process leaves the discharge regime and enters the hydrodynamic regime with an unstable gas film.<sup>[16](https://journals.sagepub.com/doi/10.1177/0954405418798865)</sup><sup> • </sup><sup>[20](http://www.nature.com/articles/s41598-026-36060-w.pdf)</sup> Other limitations are surface defects from localized overheating, low material removal rate, low depth of penetration, overcut, and taper, largely from lack of electrolyte flow at the tool point; spark-induced chipping can initiate cracks in glass.<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup><sup> • </sup><sup>[20](http://www.nature.com/articles/s41598-026-36060-w.pdf)</sup> Stabilization levers include controlling electrolyte electrochemical properties, tool electrode shape and motion, surfactants, side insulation, pulsed voltage, and ultrasonic assistance.<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> Against EDM and ECM, ECDM's combined MRR can be 5–50 times higher with decreased tool wear.<sup>[4](https://sage.cnpereading.com/doi/10.1177/0954405414534834)</sup> Unstable electrolyte conditions and inadequate flushing remain the main obstacles to industrial viability.<sup>[24](https://journal.ump.edu.my/jmes/article/view/13101)</sup>\n\nRecent work targets these limits: gas film thickness formation in Pyrex machining (Kumar, Singh, and Singh, 2024),<sup>[25](https://doi.org/10.1149/1945-7111/ad7bf3)</sup> characterization of electrolytic plasma versus spark discharge (Shunda Zhan and colleagues, 2024),<sup>[26](https://doi.org/10.1007/s00170-024-14566-9)</sup> controlled-ECDM stability studies, voltage-waveform effects on the gas film, ultrasonic-assisted rotary drilling gains of 14.8% in MRR,<sup>[19](https://www.nature.com/articles/s41598-025-92574-9)</sup><sup> • </sup><sup>[24](https://journal.ump.edu.my/jmes/article/view/13101)</sup> and optimization studies on composites, where ANOVA of aluminum 6061 reinforced with B4C and SiC found voltage the most significant factor on MRR (F = 36.61, P = 0.004).<sup>[27](https://reference-global.com/article/10.2478/mspe-2026-0012)</sup>\n\n## References\n\n1. [Fascio V, Langen H H, Bleuler H, Comninellis Ch, 'Investigations of the spark assisted chemical engraving', Electrochemistry Communications 5(3):203–207, March 2003](https://www.sciencedirect.com/science/article/abs/pii/S1388248103000183)\n2. [SACE for microfactories (Langen et al. / Wüthrich group, table-top SACE paper)](https://repository.tudelft.nl/file/File_e50536c1-aff5-4b72-a6a7-977f116447e0?preview=1)\n3. [Wüthrich R and Fascio V 2005, 'Machining of non-conducting materials using electrochemical discharge phenomenon, an overview', Int. J. Mach. Tools Manuf. 45 1095–108](https://www.sciencedirect.com/science/article/abs/pii/S0890695504002974)\n4. [Developments on electrochemical discharge machining: A review of experimental investigations on tool electrode process parameters (Gupta, Dvivedi & Kumar, Proc IMechE Part B, 2015)](https://sage.cnpereading.com/doi/10.1177/0954405414534834)\n5. [A Ghosh, 'Electrochemical discharge machining: Principle and possibilities', Sadhana 22(3):435–447](https://www.ias.ac.in/article/fulltext/sadh/022/03/0435-0447)\n6. [How small can we machine with spark assisted chemical engraving (SACE)? (Wüthrich et al., J. Micromechanics and Microengineering)](https://repository.tudelft.nl/file/File_a03f6bcc-9f96-4d1c-898b-d44a7c1f803b?preview=1)\n7. [Study of Gas Film Characteristics in Electrochemical Discharge Machining and Their Effects on Discharge Energy Distribution (Micromachines 2023, 14, 1079)](https://www.mdpi.com/2072-666X/14/5/1079)\n8. [Experimental Investigation of Discharge Phenomena in Electrochemical Discharge Machining Process (Micromachines 2023, 14, 367)](https://mdpi-res.com/d_attachment/micromachines/micromachines-14-00367/article_deploy/micromachines-14-00367-v2.pdf?version=1676465621)\n9. [Mechanism of spark generation during electrochemical discharge machining: a theoretical model and experimental verification (Journal of Materials Processing Technology, 1996)](https://doi.org/10.1016/0924-0136%2895%2902202-3)\n10. [Micromachining with ECDM: Research Potentials and Experimental Investigations (WASET conference paper)](https://publications.waset.org/8540.pdf)\n11. [Amitabha Ghosh (1997). Electrochemical discharge machining: Principle and possibilities. Sadhana.](https://doi.org/10.1007/bf02744482)\n12. [ (1998). Micro Electrochemical Discharge Machining of Glass. International Journal of Electrical Machining.](https://doi.org/10.2526/ijem.3.65)\n13. [V. Fascio, R. Wüthrich, H. Bleuler (2004). Spark assisted chemical engraving in the light of electrochemistry. Electrochimica Acta.](https://doi.org/10.1016/j.electacta.2003.12.062)\n14. [R Wüthrich and colleagues (2005). Physical principles and miniaturization of spark assisted chemical engraving (SACE). Journal of Micromechanics and Microengineering.](https://doi.org/10.1088/0960-1317/15/10/s03)\n15. [Jana D. Abou Ziki, Rolf Wüthrich (2011). Tool wear and tool thermal expansion during micro-machining by spark assisted chemical engraving. The International Journal of Advanced Manufacturing Technology.](https://doi.org/10.1007/s00170-011-3731-6)\n16. [Electrochemical discharge machining: A review on preceding and perspective research (Proc IMechE Part B)](https://journals.sagepub.com/doi/10.1177/0954405418798865)\n17. [Investigation on Wire Electrochemical Discharge Micro-Machining (WECDMM) (Micromachines 2023, 14, 1505)](https://www.mdpi.com/2072-666X/14/8/1505)\n18. [ECDM methods for fluidic interfacing through thin glass substrates and the formation of spherical microcavities (J. Micromech. Microeng. 2007)](https://iopscience.iop.org/article/10.1088/0960-1317/17/2/028)\n19. [Micro hole drilling and multi criteria optimization of soda lime glass via ultrasonic assisted rotary electrochemical discharge drilling (Scientific Reports 2025)](https://www.nature.com/articles/s41598-025-92574-9)\n20. [Nitrogen gas-assisted electrochemical discharge micro-machining of borosilicate glass (Scientific Reports)](http://www.nature.com/articles/s41598-026-36060-w.pdf)\n21. [Investigation on process enhancement in abrasive-assisted rotary mode ECDM process (Materials and Manufacturing Processes, 2026)](https://www.tandfonline.com/doi/full/10.1080/10426914.2026.2632598)\n22. [Application of the sheet electrode to enhance the geometric characteristics of micro-holes fabricated by electrochemical discharge machining (J. Mech. Sci. Technol. 2022)](https://link.springer.com/article/10.1007/s12206-022-1012-y)\n23. [Analysis on the effect of ECDM process parameters during micro-machining of glass using genetic algorithm (JMES 2018)](https://journal.ump.edu.my/jmes/article/view/569)\n24. [Electrochemical discharge machining for micro fabrication of insulating brittle material: State of the art and future directions (Journal of Mechanical Engineering and Sciences)](https://journal.ump.edu.my/jmes/article/view/13101)\n25. [Rakesh Kumar, Ravi Pratap Singh, Satnam Singh (2024). On the Machinability and Formation of Gas Film Thickness in ECDM of Silica based Pyrex Glass. Journal of The Electrochemical Society.](https://doi.org/10.1149/1945-7111/ad7bf3)\n26. [Shunda Zhan and colleagues (2024). Towards a better understanding of the characteristics of electrolytic plasma discharge and spark discharge in ECDM. The International Journal of Advanced Manufacturing Technology.](https://doi.org/10.1007/s00170-024-14566-9)\n27. [Advanced Electrochemical Discharge Machining and Process Optimization for Hybrid Metal Matrix Composites (Management Systems in Production Engineering, 2026)](https://reference-global.com/article/10.2478/mspe-2026-0012)\n\n---\n*Topic: Encyclopedia › Technology and the built world › Engineering and manufacturing › Manufacturing processes and fabrication › Machining and machine tools*\n\n*Initially written Sep 29, 2026 · Edited: Oct 15, 2026*\n\n*Copyright 2026 EdgeChat AI, a subsidiary of Biostate AI.*\n\nLicense: Edgepedia Community License 1.0, https://www.edgepedia.org/edgepedia/license\n",
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 "speakable": "Electrochemical discharge machining, also known as spark assisted chemical engraving, is a micromachining process that machines nonconductive materials like glass, quartz, and ceramics for MEMS devices."
}
