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The feasibility of building copper‐based electrodes for electrical discharge machining (EDM) via laser cladding is investigated as an application of rapid prototyping (RP). Two material systems‐Cu/W (with and without nickel) and Cu/B4C (with and without nickel) in certain compositions are selected for the experimental investigation. The laser claddings are realised via a 3000 W CO2 laser with suitable parameters. The micro‐structures of the electrodes are analysed with a SEM. The performance of the EDM electrodes is examined in terms of machining rate and wear rate.

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