Removing aerospace fasteners has always been a time-consuming, high-risk task. Traditional drilling methods can be slow, inconsistent, and often result in costly structural damage or rework. The E-Drill system, developed by Perfect Point EDM, takes a completely different approach, using advanced Electro-Discharge Machining (EDM) technology to remove fasteners quickly, safely, and without harming the parent material.
This post explains how E-Drill works, what makes it different from traditional drilling, and why leading aerospace OEMs, MRO facilities, and military depots rely on it for critical maintenance operations.
E-Drill is a handheld plunge EDM tool designed specifically for aerospace fastener removal. Unlike a standard drill that cuts through material mechanically, E-Drill uses controlled electrical energy to erode the fastener metal with incredible precision.
Here’s a simplified look at the process:
- Precise Alignment:
The E-Drill handpiece is aligned over the fastener head using a locator tool or bushing. This ensures the electrode is perfectly centered, preventing off-axis cuts or hole elongation. - EDM Spark Erosion:
A circular copper electrode, energized by the control unit, creates thousands of micro electrical discharges per second. These discharges erode the fastener material without making physical contact, machining a precise groove just under the head. - Continuous Flushing:
Deionized water is flushed through the cutting area to cool the process and remove microscopic debris. This keeps the worksite clean and eliminates the large metal chips produced by traditional drilling. - Fastener Release:
Once the groove is complete, a simple punch tool pops the head off cleanly. The shank is pushed through later, leaving the underlying structure undamaged and ready for the next step in the repair process.
Why E-Drill is Different from Drilling
Traditional twist drills and carbide bits physically cut through fasteners, which often leads to:
- Slipping or “walking” off the fastener head
- Enlarged or elongated holes that require costly oversizing or repairs
- Frequent drill bit replacement, especially with hard-metal fasteners
- Operator fatigue and increased risk of injuries
- Metal chips and debris creating foreign object damage (FOD) concerns
E-Drill eliminates these issues by using non-contact EDM cutting, resulting in:
- Damage-free removal – Only the fastener is eroded, preserving the surrounding structure
- Consistent depth control – Each fastener is machined to the exact programmed depth
- Faster cycle times – High-strength fasteners like titanium can be removed in seconds
- Longer-lasting consumables – Electrodes last for dozens of removals, reducing costs
- Minimal debris – Less cleanup and lower FOD risk in critical aircraft environments
Where E-Drill is Used
E-Drill is trusted across a variety of platforms, including:
- Commercial aircraft during heavy maintenance checks
- Military fighter jets and transport aircraft undergoing depot-level repairs
- Rotorcraft structures with mixed-metal fasteners
- Space and advanced engineering programs requiring precision fastener removal
With thousands of fasteners on every aircraft, the ability to remove them safely and efficiently saves significant time and money for operators and maintenance providers.
Learn More or See E-Drill in Action
E-Drill is redefining aerospace fastener removal by replacing outdated drilling techniques with a precision, non-damaging, repeatable process. To explore how it can improve your maintenance operations:
- Visit the E-Drill product page
- Contact our team at info@ppedm.com for technical details or a custom ROI analysis
- Schedule a live demo at your facility to experience E-Drill firsthand