The inner diameter of small-diameter tube electrodes can easily collapse when cutting the electrode to size, preventing proper flushing and becoming detrimental to the performance of the machine.

Avoid cutting the tube electrode using scissors or cutting pliers, which can damage or crush the electrode, restricting or preventing fluid flow and flushing through the electrode during machining. As a result, the OD may be misshapen and not fit through the guide.

Instead, to accurately cut a tube electrode, use a flat, hard surface and a straight razor. Roll the electrode across the flat surface with the razor on top and with light pressure. This will cut the electrode to length with minimal damage and distortion to both the ID and OD surfaces