EDMs require several consumables to ensure top performance. These include power feeders, filters and resin.

Power feeders are located in the upper and lower heads and transmit the current to the cutting wire. They wear at different rates depending on wire size and power levels. As wear increases, cutting speed decreases. If cutting speed drops, power feeders may require indexing or replacement. Indexables take about 15 minutes to index and clean, and this should be done as dictated by the hour meter.

Filters clean the cutting sludge from the DI water for recirculation. They come in many different sizes, shapes and quantities; using the proper size and flow is important for circulation and machining stability. As the load in the filters increases, circulation volume decreases. Life expectancy is controlled by cutting speed, wire size, material type and thickness. They need to be changed in accordance with the filter back pressure reading or volume loss requirements.

The DI (de-ionizing) resin system contains anion and cation resin beads in a cylinder.It removes the ions from the water generated by the cutting process and controls the conductivity of the water. Life expectancy depends on the make-up of the water added, material being cut, filter condition and the machine power supply type. Maintaining proper DI resin levels will prevent unstable machining. Pre-filters can be used to extend resin life. Resin exchange is required when the machine puts up a warning that the conductivity level is too high. Change time is only about 10 minutes.