Wire electrical discharge machining (WEDM) is a precision machining process that uses electrical discharges struck between an axially moving wire electrode and the workpiece to remove material through melting and vaporization. WEDM is replacing traditional processes like broaching for machining safety-critical components such as the turbine disk in the manufacture of fuel-efficient jet engines. The main issue preventing the more widespread use of WEDM is that due to WEDM being less productive than broaching, it currently requires 6 WEDM machine tools to replace a single broaching machine to maintain the same throughput. The main factor limiting WEDM productivity is wire breakage. To increase the Cutting Rate (CR) more power is required, and increasing power also increases the likelihood of breakage. The goal of this research is to determine whether wires thicker than the conventional 0.25 mm diameter will both optimize the cutting rate and minimize breakage. Thicker wires will allow for an increase in the duty factor, with a significantly decreased incidence of wire breakage. Given that an increased wire diameter also increases the kerf width, this research seeks to identify the optimal wire diameter that maximizes the linear cutting rate. This research concluded that using wire of optimal diameter in WEDM increases the CR by as much as 400%. / Thesis / Master of Science in Mechanical Engineering (MSME) / In order to secure jet engine blades onto the engine, complex features called Firtree Root Forms (FTRF) are used. These features need to be very precisely cut in order for the engine to work at peak efficiency. Currently, industry is using a manufacturing process called broaching to machine these FTRFs, however broaches wear out over time, which causes imprecise cuts. The solution to this is to use Wire Electrical Discharge Machining (WEDM). The problem with WEDM is that it takes on average 6 machines to replace a single broaching machine in terms of productivity. The objective of this project is to increase the cutting speed (and thus productivity) of WEDM, and one of the ways to do that is to increase the electrode wire diameter. This allows for more power to be used in the machining process without the risk of wire breakage, which is a major problem when cutting with WEDM. The research presented in this thesis successfully demonstrates that using thicker wires in WEDM can cut as much as 400% faster than the wires currently in common use in industry.