Abstract Wire EDM is a time consuming process which requires several, (cost significant), consumables like wire, filters or deionization resin. Based on machining history and sensor inputs a developed model, e.g. an intelligent software, allows to predict the status & future capacity of consumables and wear parts and thus avoid down-times of machine. The use of a predictive model for estimation of the lifetime of consumable and wear parts will be a significant step in the automation of (wire EDM) machines.