The PCD Edge system from Methods EDM, Sudbury, Maine (www.methodsmachine.com)profiles polycrystalline diamond (PCD) cutting tools using a Fanuc iC series wire EDM machine. The system, which can create original profiles or resharpen worn PCD-tipped tools, consists of programming/ probing/cutting software, a microfinish power supply/generator optimized for cutting PCD, a Hirschmann rotary axis, a Renishaw probe (mounted on the EDM machine) and a tool-clamping system. Users design tool-edge contours on their own CAD systems, and the PCD Edge software provides input masks to simplify parameter selection, program simulation, design modification and verification. With no special programming knowledge, users can create up to eight profile sections with specific parameters for each. The software and rotary axis permit adjustment of the relief angles on each contour element as well as automatic measuring (with feedback) of 3-D PCD rake and shear angles. With optional control software, the entire process can be automated for unattended operation.