For more than two decades, Master Cut EDM’s founders Harold Bartman and Scott Phillips have put their 90+ years of combined industry experience to work for our customers. Together, they’ve assembled a top-notch team of skilled and experienced metalworking specialists who match Master Cut machining solutions to our automotive, defense, medical, aerospace and packaging customers’ requirements.

When our client needed a tool steel headlight mold for an injection-molding application used in the automotive industry, we used wire electrical discharge machining on our state-of-the-art Makino U86 wire EDM. Part of Makino’s award-winning U-series of wire EDM machines, the U86 offers true work-piece accuracy, superior surface finishes and faster cycle times. For this customer, the U86 cut pockets and round holes and produced tight tolerances of +/-.0005 location and +/-.0002 size. We confirmed that it met the customer-supplied specifications using gage pins and blocks.

H-13 hardened tool steel was used because it stands up to extreme heat while also offering thermal fatigue shock and breakage resistance.

In just three days, Master Cut wire electrical discharge machined two of the 5,000 lb parts for delivery within Illinois.

For more details on this project, please see below and feel free to contact us for additional information on this project and our services.


Product Description
  • This headlight mold is used within an injection molding application
Capabilities Applied/Processes
  • Wire EDM
    • Cut Pockets
    • Cut Round Holes
Equipment Used to Manufacture Part
  • Makino U86 wire EDM
Overall Part Dimensions  

  • Length: 38″
  • Width: 28″
  • Height: 19.5″
Tightest Tolerances Required
  • +/-.0005 location, +/-.0002 size
Material Used
  • H-13 Hardened Tool Steel
In process testing/inspection performed
  • Verified using gage pins and blocks
Industry for Use
  • Automotive
Block Weight
  • 5,000lbs
  • 2 Units
Turn Around Time
  • 3 Days
Delivery Location
  • Illinois
Standards Met
  • Customer supplied specifications
Product Name
  • Headlight Mold

Call our office at 847.534.0343 to speak about your project.

With a combined 90+ years of experience and a team that is able to work 24 hours a day we are pleased to offer expedited production and delivery on high precision, wire EDM and hole popping projects.