Maximizes the accuracy and repeatability of wire Electrical Discharge Machines (EDM) through fixturing and controlled cutting methods. Also optimizes mathematical algorithms for the cutting path. Presents results slowing the verified generation of precise spur gears in pitches ranging from 5 to 41 DP. Demonstrates the advantage of this method@ including short lead times (with accuracy approaching form ground gears) at a competitive cost. Concludes this method is suitable for producing small to medium lots of accurate spur gears in any electrically conductive material.