One of the most common questions we receive about the E-Drill Fastener Separation Technology is whether it can harm the airframe or structure during the fastener removal process. The short answer is that E-Drill is specifically engineered to avoid structural damage—and independent testing confirms its safety and reliability compared to traditional drilling methods.
Precision-Engineered to Protect the Parent Material
Unlike mechanical drilling, E-Drill uses a controlled Electro-Discharge Machining (EDM) process that cuts only the fastener itself. The system is guided by mechanical bushings or vacuum locator tooling, ensuring perfect alignment over the fastener head. It then removes material inside the fastener shank to a pre-programmed depth, undersized compared to the hole diameter, stopping well before it could touch the surrounding structure. This built-in safety factor makes unintended contact with the parent material highly unlikely.
Proven Results in Laboratory Testing
Multiple independent studies and in-house analyses confirm that:
- When operated correctly, E-Drill does not touch or alter the surrounding material.
- Thermal impact to the parent structure is negligible, often lower than that caused by conventional drilling, even under worst-case offsets.
- Tests examining recast layers, heat-affected zones, and microcracking show no harmful effects to the structure as long as the electrode remains within the fastener.
- Even in forced misalignment scenarios (beyond normal operating tolerances), any contact damage can be rectified using standard aerospace repair practices—typically by oversizing the fastener hole, restoring full structural integrity as validated by fatigue testing.
Note: for more information on, or to view any of these test reports, please contact us.
Why E-Drill Is Safer Than Traditional Drilling
Traditional twist drills rely on high force, spinning cutters, and repeated drilling passes to remove hard-metal fasteners. This method increases the chance of drill wander, hole elongation, and substructure damage. It also generates heat and metal shavings (FOD) that can harm both the structure and the technician.
E-Drill’s forceless, guided, water-cooled process eliminates these risks:
- No downward force on the structure
- Controlled, concentric cuts every time
- Built-in clearance from the parent material
- Reduced debris and minimal cleanup required
In the Rare Case of User Error
While rare, if misalignment or improper setup causes EDM contact with the structure, existing, approved aerospace repair procedures apply. Independent lab studies confirm that a standard “first oversize” or “second oversize” reaming process completely removes any EDM-affected material, leaving the structure as sound as it was before.
The Bottom Line
E-Drill is purpose-built to remove fasteners faster and safer than traditional methods, with multiple safety factors preventing structural damage. In the unlikely event of misalignment, the damage is predictable, detectable, and repairable using standard industry practices—no additional risk to the airframe or component integrity.
For a detailed look at the test results and validated repair processes, please contact us.