EDM Hole Drilling

Precision EDM Drilled Holes For R&D and Contract Manufacturing



EDM Intelligent Solutions offers unique, EDM Hole Drilling services of blind and through holes. Our purpose-built CNC operated EDM holepopping machines can produce holes as small as 300 microns (0.0120”) in some of the toughest conductive materials available like carbide and nickel. High precision hole sizes, excellent hole edge quality, superior surface finish, improved overall part accuracy and excellent hole consistency are achieved through the use of cutting edge EDM generator technologies and electrode materials.



Similar to Sinker EDM, hole drilling with electrical discharge machining uses electric current, carried to the workpiece through a pipe shaped electrode, to erode or burn away conductive materials. The electrode doesn’t ever touch the material being machined so deflection of the pipe electrode is minimized when compared to drilling holes with a traditional cutting tool. During EDM Holepop the tube electrode is energized and spun at high speeds while high pressure flushing is pumped through the tube to flush out the workpiece material that is being cut away. This process allows EDM Intelligent Solutions to produce fast and accurate holes in all types of conductive metals.  Our EDM Drilling machines are designed for the highest levels of accuracy, incredible reliability, and feature uniquely integrated automation that offers increased productivity which makes EDM Hole Drilling the perfect choice for projects with hole quantities ranging from just a few all the way up to high volume production applications requiring thousands of holes.

Sinker EDM - EDM Department Inc


Drilling accurate and repeatable holes in extremely hard materials is no easy process. Harnessing decades of tight tolerance Sinker EDM experience, the team at EDM Intelligent Solutions is able to effectively machine holes in some of the toughest conductive materials available. For 25 years we have been offering standard tolerances (0.0010″ to 0.0005″), as well as high precision tolerances as tight as 0.0001″ (2 micron) for an array of industries and applications. Our 3-Axis and 5-Axis CNC hole drilling electrical discharge machinery have the capacity to run multiple pipe electrode sizes, ranging from 0.3mm (0.0120″) to 4mm (0.1575″) in diameter.

We partner with suppliers worldwide to ensure continuous access to and timely delivery of hole popping electrodes made to our exacting requirements from a variety of standard and exotic materials. This ensures that our EDM hole poppers are never left waiting for pipe electrodes to arrive while the drilling process is active 24/7. Extreme machining efficiencies are possible due to the integrated automation that changes both pipe electrodes and workpieces with no human intervention. This enhances overall productivity and saves our customers’ time and money. Our decades of EDM machining experience and state-of-the-art equipment enable us to provide repeatable quality parts and components from any type of conductive material.

We are continuously working with our technology partners to upgrade our CNC EDM hole drilling capabilities to meet the ever-evolving needs of our diverse base of customers. We also complement our EDM precision hole drilling capabilities with other manufacturing services like Precision Grinding and Micro Milling, as well as 3D measurement of machined components for full quality assurance.


EDM Hole Drilling Specifics:

  • Advanced 3-Axis and 5-Axis CNC Hole Drilling EDMs built for efficient 24/7 operation
  • Multiple pipe electrode materials are used like brass, copper and tungsten
  • Workpieces up to 4″ thick are easily machined using EDM Hole Drilling
  • Standard machining tolerances of 0.0010″ to 0.0005″ and high precision tolerances as tight as 0.0001″ (2µm micron)
  • Micromachining Fine Hole EDM Drilling tolerances of 1µm and below
  • Feature Aspect Ratios up to 38:1
  • Finished EDM drilled hole diameters from 0.3mm (0.0120″) to 4mm (0.1575″)
  • Fine (micro) EDM drilled hole diameters as small as 40µm
  • Surface Finishes down to 4Ra µin (micro inch) eliminate finishing and require no additional polishing
  • Small quantities of 1-50+ pieces
  • Contract Manufacturing of full production quantities of thousands of pieces
Sinker EDM - EDM Department Inc


EDMIS strives to meet your specific needs. Through strategic sourcing partnerships with a vast array of qualified material suppliers nationwide, we can manufacture your components from the exact materials that you require. Strict quality standards are met by all vendors and material suppliers to EDM Intelligent Solutions to ensure that the components we produce can meet the highest standards commonly required by the Aerospace, Automotive, Communications, Defense, Medical and Scientific industries.

When it comes to materials, EDM Hole Drilling is compatible with a large range of metals that conventional machining, like milling and turning, are not always cut out for. Hardened materials like tungsten carbide are no match for the EDM Hole Drilling erosion process. Softer materials like copper are gently drilled by the energized pipe electrodes and extremely thin materials are protected from damage and accurately machined since the electrode never actually makes contact with the workpiece.


EDM Hole Drilling Compatible Materials

EDM Intelligent Solutions has completed thousands of EDM Hole Drilling projects using a diverse set of materials including those listed below. Don’t see your specific material on the list? Contact us to determine if that material can be cut using CNC Electrical Discharge Machining and how EDMIS can source that material for you.

  • Aluminum
  • Brass
  • Copper
  • Exotic Metals
  • Molybdenum
  • Titanium
  • Tungsten
  • Carbide
  • Tool Steels
  • A-2, A-5, A-6, A-8
  • D-2, D-3, D-5
  • DC-53
  • H-11, H-12, H-13, H-19
  • L-6
  • M-1, M-2, M-3, M-4, M-42
  • O-1, O-6
  • S-1, S-7
  • T-1
precision hole drilling


When components require extremely accurate and deep blind holes and/or through holes, EDM Hole Drilling should be considered. EDM Hole Drilling services are well suited for parts requiring intricate tolerances, the limitation of material stress and thermal heating, and those needing superior surface roughness finishes. Sinker EDM Hole drilling is sometimes the only machining method that can produce quality holes when materials that are too hard or too brittle are required by design. Conventional machining methods like CNC drilling will wear out many drills for just a few holes while EDM Hole Drilling pipe electrodes can produce hundreds of holes each. Through integrated machine automation, the quantities of parts being completed can easily be scaled up to meet the high volumes required by some of our largest customers.

This is just a small sample of all the types of components that EDM Intelligent Solutions has manufactured using our advanced EDM Hole machining processes. There really aren’t many types of parts that EDMIS has not worked on in some form over the last 25 years serving these industries. No project is too big or part too complex or tolerance too tight for EDM Intelligent Solutions which makes us the preferred partner for OEM manufacturers nationwide. To learn more about how EDMIS can help you contact our manufacturing team with your request for quote.


Sample EDM Hole Drilling Applications

  • Interconnect Components – holes for electrical contacts
  • Fiber Optic Components – holes for glass fiber optics
  • Medical Components – holes for drug delivery systems, surgical implants and tooling
  • Optical Lenses – holes lens arrays and assemblies
  • Research & Development – holes for particle sensors and accelerator components
  • Aerospace Industry – holes in jet engine turbine blades for cooling and fuel nozzle holes
  • Automotive Industry – holes in fuel injectors
  • Plastic Injection Molding – holes used as venting for injection molds
  • Cutting Tool Industry – holes used for inline through the tool liquid cooling and flushing
precision hole drilling

Competitive Electrical Discharge Machining Solutions

As our name suggests, EDM Precision Hole Drilling is one of our main service offerings. Over the past 25 years, we’ve completed thousands of EDM Hole Drilling projects. What differentiates EDM Intelligent Solutions manufacturing services from the competition is our ability to not only hold micron tolerances but to do so while still offering globally competitive pricing and lead times. Utilizing our vast knowledge of EDM Hole Drilling techniques and decades of industry experience, we are confident that we can produce your most challenging components to your exact specifications. To learn more about how EDMIS can help you, contact our manufacturing team with your request for a Precision Hole Drilling quote.


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