Because of its versatility, manufacturers use EDM wire cut machine operation for an extensive range of applications. Because the process can cut very small pieces, it is often an ideal choice for the production of small, highly detailed items that would normally be too delicate for other machining options. Additionally, the process is cost-effective for low quantity projects and can prove to be beneficial in prototype manufacturing, even if the actual project is carried out by different means.

It is important to remember that the wire in the process is constantly moving, and not to be reused. As a result, the copper, brass, or other metallic wire can be miles long, adding cost to the process. And, while the process uses no force and thus does not cause burrs and can be used on delicate items, the possibility of thermal stress is certainly present.

Most machining operations using wire EDM begin with a rough pass with a fairly fast feed rate and high dielectric flow. Successive skim passes take smaller cuts with a reduced dielectric flow to bring finished surfaces into tolerance. The reduced dielectric flow avoids distorting the wire during these skim passes. Cuts that do not begin along an edge of a part (such as holes) require predrilling to allow the wire to thread through.