Perfect Point demonstrated its E-Drill fastener-removal system at NBAA-BACE, using electro-discharge machining to remove aircraft fasteners without the shavings, heat transfer and foreign-object debris associated with conventional twist drilling. The company’s chief executive, Jim Becker, said a trial on a US Air Force F-15 reduced removal time by 90%, with the tool taking about 10 seconds per fastener compared with several minutes using traditional methods.
The process begins with the technician selecting the fastener and material type on the tool’s display. A vacuum-held locator is then aligned over the fastener, allowing a precision-sized electrode to cut through the fastener head to a controlled depth. A separate Single-Shot air punch removes the cut head.
The system is intended for demanding materials such as titanium and can remove riveted fasteners, including blind rivets. An adapter accommodates round rivet heads.
By avoiding chips and limiting heat transfer, the process is designed to reduce the risk of structural damage and foreign-object contamination during maintenance. The reported reduction in removal time could also lower labour requirements and aircraft downtime, although independent test data, certification information, pricing and details of current commercial operators were not provided.