Small hole drilling, often called hole pop EDM, uses a hollow round electrode to produce precise high aspect ratio holes in a wide range of conductive materials. Using controlled electrical discharges, or spark erosion, the process removes material without direct contact. This makes it ideal for hard metals, heat treated components, and delicate parts where traditional drilling may cause stress or distortion. Hole size is determined by the electrode diameter, delivering consistent accuracy and repeatability.
A continuous flow of dielectric fluid moves through and around the electrode during machining, providing cooling while flushing away eroded particles. This helps produce clean holes with minimal burrs and strong surface integrity, even at greater depths or in complex geometries.
CNC controlled hole drilling EDM allows for fast automated production of single or multiple holes with precise positioning and minimal operator involvement. This improves efficiency, reduces setup time, and ensures consistent results in both prototype and production environments.
Hole pop EDM is commonly used to create start holes for wire EDM, vent holes, coolant passages, ejector pin holes, and other blind or through holes. It is also highly effective for removing broken taps, drills, or fasteners without damaging the surrounding material. Its versatility and precision make it a valuable solution for industries such as aerospace, medical, tooling, and advanced manufacturing.