When it comes to aircraft maintenance and teardown operations, precision and efficiency are critical. Removing thousands of hard metallic fasteners from advanced structures can be time-consuming and risky, especially when traditional drilling methods are used.
To better understand and document the advantages of E-Drill over conventional fastener removal techniques, Perfect Point EDM partnered with the National Institute of Aviation Research (NIAR) for a multi-phase test program focused on structural teardown of aging jet fighter aircraft.
Objective Data on Fastener Removal Performance
The test program, conducted at NIAR’s Aging Aircraft Lab in Wichita, Kansas, involved three fighter aircraft that were artificially aged through fatigue testing. The goal: to gather objective, high-fidelity data comparing E-Drill’s performance to standard twist-drill processes in several key areas:
- Damage Reduction: Measuring skin and substructure integrity after fastener removal
- Foreign Object Debris (FOD): Quantifying how E-Drill reduces the risk of FOD generation
- Consumable Costs: Tracking electrode and tooling use compared to drill bits and other traditional consumables
- Process Speed and Accuracy: Demonstrating cycle time improvements and repeatable results
By aligning E-Drill concentrically to the fastener shank and using a controlled EDM process, technicians can remove even the hardest fasteners in seconds while eliminating the risk of elongating or damaging the hole. This precision is expected to stand out clearly in NIAR’s data.
Expert Oversight from NIAR
The program is led by Dr. Melinda Laubach-Hock, Director of NIAR’s Aging Aircraft Lab, who has more than 16 years of experience performing structural teardowns for both commercial and military platforms. Her team’s methodology isolates detail parts with minimal disassembly-induced damage, providing high-fidelity inspection results that reveal even minor structural anomalies such as cracks.
In addition to experienced MRO technicians, Wichita State University students were involved in the project, gaining valuable hands-on experience with next-generation maintenance technology—a step toward bridging workforce gaps in aerospace engineering and teardown programs.
Why This Matters for Aerospace Maintenance
The ability to remove thousands of fasteners quickly, safely, and without structural damage has a direct impact on aircraft maintenance costs, turnaround time, and safety. While anecdotal results from E-Drill adoption have already shown significant benefits, NIAR’s independent, data-driven testing will:
- Help OEMs, MROs, and military organizations make informed decisions about adopting new technology
- Validate the long-term cost savings associated with reduced rework, lower consumable use, and minimized FOD risk
Read the Full Report
This program represents an important step toward industry-wide recognition of E-Drill as the preferred fastener removal tool for advanced aerospace structures.
You can access the full test program release and details here: For more info read the full release
