The popularity of 3D printing has spurred a competition to make automated machine tools and fabrication methods more accessible to hobbyists. Laser cutting is a great example of this, as it used to be too expensive for hobbyists, but now can be purchased for a few hundred dollars. However, these laser cutters are not powerful enough to cut through metal, which is why the new Powercore desktop EDM machine is so desirable, as it can cut through sheet metal. If you’re looking to make a project quickly, you do not have to wait days or weeks for laser-cut components to arrive when you can get high-quality parts in minutes with Electrical Discharge Machining (EDM). The Powercore is an ideal tool for Makers, as it is similarly priced to laser cutters, but can cut solid aluminum much faster.

EDM is a process that uses sparks to cut thin lines in hard metals like tool steel, which would be difficult for conventional mills to handle. It is a clean process that does not require powerful motors, as there is no physical contact between the tool and the material, thus requiring very little torque. This makes it suitable for desktop use, as the machine can be small and lightweight. The sparks are created by pulsing electricity between two electrodes with sheet metal in between them, and the electrodes are moved around the material at a relatively slow pace.

EDM is much more gentle than traditional subtractive manufacturing, making it an attractive option for home labs. Unlike metal-capable CNC mills which require large castings to contain cutting forces, EDM can use light-duty structures and still produce precise parts. Powercore is an example of this, as it is designed to replace the extruder of a 3D printer and is composed of parts that can be printed on the same machine.

EDM is a more attractive option for home labs than traditional subtractive manufacturing due to its gentleness, and it can produce precise parts with light-duty structures, unlike metal-capable CNC mills which require large castings to contain cutting forces. Powercore is designed to replace the extruder of a 3D printer and is composed of parts that can be printed on the same machine.

Rack Robotics claims they have been able to cut material as thick as 4mm, but suggest keeping it below 1mm for the small vat with a standard material stock of 3×3″ aluminum sheet. Cut rates are estimated to be around 10mm per minute. Rack Robotics suggests that the Powercore is best suited for cutting small, thin aluminum sheet metal parts that require precise, clean edges, as well as delicate parts that would be difficult to fabricate with conventional methods without damage. It is not suitable for cutting large sheets, very thick sheets, or fast jobs.

Rack Robotics‘ Powercore is currently on Kickstarter with a goal of $5,000, and has already raised over $120,000, showing how enthusiastic the hobbyist community is about this product. The Kickstarter campaign will end on April 1st, and the special price is $399. The package includes a power supply, ten brass electrodes, 10 pieces of aluminum stock, two electrode holder kits, and a work-holding kit.

However, backers will need to print some parts themselves in order to complete the build, and rewards are expected to be shipped out in July 2023.