Sodick Sodick AL100G+
Key Specifications
X Travel
Y Travel
Z Travel
max workpiece weight
max electrode weight
drive system
Overview
The Sodick AL100G+ is the flagship of Sodick's AL G-Plus series, a massive linear motor die-sinker EDM with 1,200 x 650 x 500 mm (47.2 x 25.6 x 19.7 in) X/Y/Z travel and a 5,000 kg (11,023 lb) maximum workpiece capacity. This machine occupies the top tier of Sodick's sinker EDM lineup, targeting the largest die and mold applications in automotive, aerospace, and heavy industrial tooling where no smaller machine can cover the required cavity geometry.
All three axes are powered by Sodick's direct-drive linear motors. At 1,200 mm of X-axis travel, the advantages of eliminating ball screws are amplified: a ball screw of this length would generate significant thermal expansion and mechanical compliance under the loads imposed by a 5,000 kg workpiece. The AL100G+'s linear motors sidestep these physics entirely, delivering sub-micron positioning resolution and zero backlash across the full travel range.
The AL100G+ incorporates Sodick's LN Pro AI machining condition adviser, which leverages artificial intelligence to recommend and optimize discharge parameters based on the specific combination of electrode material, workpiece material, and target surface finish. The TH COM (Thermal Commit) thermal displacement correction system monitors and compensates for thermal drift during the extended burn cycles that large-cavity work demands.
At 3,820 x 4,200 x 3,340 mm (150 x 165 x 132 in) overall dimensions including power supply and dielectric tank, the AL100G+ is a major facility commitment. Installation requires reinforced foundations, high-capacity overhead cranes, and sufficient service clearances for electrode handling and workpiece loading. Pricing for a new AL100G+ typically ranges from $400,000 to $550,000, placing it among the most expensive sinker EDMs available.
Full Specifications
| Parameter | Value |
|---|---|
| X-Axis Travel | 1,200 mm (47.2 in) |
| Y-Axis Travel | 650 mm (25.6 in) |
| Z-Axis Travel | 500 mm (19.7 in) |
| Max Workpiece Weight | 5,000 kg (11,023 lb) |
| Max Electrode Weight | 100 kg (220 lb) |
| Drive System | Linear motors (X, Y, Z axes — screw-less) |
| Ai System | LN Pro AI machining condition adviser |
| Thermal Compensation | TH COM (Thermal Commit) thermal displacement correction |
| Machine Dimensions | 3,820 x 4,200 x 3,340 mm (150 x 165 x 132 in) incl. power supply/dielectric tank |
| Positioning Resolution | 0.1 um |
| Surface Finish | Ra 0.1 um achievable with fine-pulse finishing |
| Energy Optimization | Automated pump optimization for reduced power consumption |
| Axis Stroke Xyz | 1200 x 650 x 500 |
| Max Weight Of Electrodekg | 100 |
| Max Weight Of Workpiecekg | 5000 |
| Machine Tool Dimensions W X D X H | 3820 x 4200 x 3340*1 |
Specifications sourced from sodick.co.jp — verified 2026-03-28
Strengths & Limitations
Strengths
- 1,200 x 650 x 500 mm travel is among the largest available in any linear motor sinker EDM — covers the biggest automotive stamping dies and aerospace mold cavities
- 5,000 kg workpiece capacity handles the heaviest die blocks and mold bases with margin for robust workholding and fixturing
- Linear motor drives on all axes maintain sub-micron positioning accuracy across the full 1,200 mm X travel
- LN Pro AI machining condition adviser optimizes discharge parameters automatically, reducing setup time
- TH COM thermal displacement correction maintains dimensional accuracy during multi-shift unattended burns
- Automated pump optimization delivers measurable energy savings during continuous around-the-clock operation
Limitations
- At 3,820 x 4,200 mm footprint, the AL100G+ requires significant floor space, reinforced foundations, and high-capacity overhead crane access
- Price range of $400,000-$550,000 is among the highest in the sinker EDM category
- The massive dielectric tank volume requires substantial fluid inventory and sophisticated thermal management
- Lead times for large-format linear motor sinker EDMs are typically 6-12 months
Best For
Frequently Asked Questions
01
The AL100G+ provides significantly more travel — 1,200 x 650 x 500 mm versus the AL80G+'s 850 x 520 x 420 mm — and increases workpiece capacity from 3,000 kg to 5,000 kg. Both share linear motor drives, LN Pro AI, and TH COM thermal compensation. The AL100G+ is necessary when die cavities exceed the AL80G+'s travel envelope or when workpiece weights exceed 3,000 kg.
02
A machine of this size and workpiece capacity requires a reinforced concrete foundation engineered for the combined weight of the machine, dielectric fluid, and maximum workpiece load. Sodick provides detailed foundation drawings specifying concrete depth, reinforcement, isolation requirements, and leveling point locations.
03
Yes, the AL100G+ supports optional automatic electrode changers (AEC) for unattended multi-electrode sequencing. Combined with the LN Pro AI condition adviser and TH COM thermal compensation, the machine can execute complex multi-electrode burn sequences across shifts without operator intervention.
04
With proper electrode material selection and multi-stage finishing sequences, the AL100G+ achieves Ra 0.1 um mirror-class finishes. Standard production roughing and semi-finishing yields VDI 12-18 (Ra 0.4-1.0 um). Fine-pulse finishing with graphite or copper electrodes reaches VDI 4-8 (Ra 0.10-0.25 um).
