The EDM Tool Revolutionizing Fastener Removal in Aerospace Maintenance

“Removing a fastener” sounds fairly simple. In aerospace, however, it rarely is.

Corroded bolts and flush rivets are often present on aircraft under maintenance, which are difficult for technicians to remove. What’s more, a single stubborn fastener can take five minutes to remove with a conventional drill, considering nothing goes wrong. For a component with hundreds of rivets, this time adds up fast.

Perfect Point EDM built its E-Drill system to fix that exact problem.

How the E-Drill Works

The E-Drill is a handheld electrical discharge machining device, the first of its kind designed specifically for fastener removal in aerospace applications. While most conventional drills physically spin a drill bit into metal, the E-Drill uses this electrical discharge technology to cut through it.

The result is a perfectly cut circle in the center of the fastener, without any shavings, heat, or foreign objects left in the airframe. And best of all, this cut takes mere seconds.

The process is straightforward. Perfect Point Marketing Manager Nils Besvold outlined the process to AeroXplorer at MRO Americas in April.

First, the technician lines up the tool over the fastener. A vacuum system locks it in place, with a magnifying glass to provide additional guidance in alignment. The device comes pre-programmed for the specific fastener type, so it knows exactly how deep to cut.

Once alignment is verified, the operator can simply pull the trigger to initiate the cut. A green light signals completion. The cut goes right to the bottom of the countersink, leaving a weak point that an air punch breaks apart in a single blow. The fastener comes out in two pieces, clean and fast.

Besvold commented on the process, “If you’re using a drill, the bit can walk off-center, elongate the hole, or damage the surrounding structure.” He added, “It’s quick, it’s clean, and there’s much less damage because it’s so accurate and controllable.”

A Full Range of Fasteners

The E-Drill handles a variety of fastener types, including aluminum, titanium, Hi-Loks, rivets, and others typically found across commercial and military aircraft. Various major industry players have integrated the E-Drill into their daily operations. Even maintenance schools, such as Tulsa Tech, have trained specifically on the Perfect Point system to prepare for competitions and real shop use. 

Other Products

Perfect Point also produces the S-Blaster, a companion tool for spot coating removal. It pulls coatings, sealants, and corrosion off fastener areas in a closed loop system with HEPA filtration, designed to be used without masks or containment shrouds. 

According to its website, the company also offers live demos, an online shop for accessories and consumables, and training for the E-Drill through its “E-Drill Academy” support pages.

For a maintenance industry that has relied on the same drilling techniques for decades, Perfect Point is offering a new technology that not only simplifies the fastener removal process, but also makes it considerably faster.

In the past, five minutes per fastener was normal. But now, all you’ll need is seven seconds.