EDM Hole Drilling Machines
Reviewed by Steve Brown, Founder & EDM Specialist at Iron Machine Tool | 15+ years with Mitsubishi Machinery Systems
EDM Hole Drilling Machines
Precision EDM Hole Drilling Machines for Minnesota Manufacturers
EDM hole drilling machines also called fast hole EDM or small hole EDM drills use a rotating tubular electrode and electrical discharge energy to pierce small, precise holes through hardened, exotic, and difficult-to-machine metals. Whether you need a single start hole for wire EDM threading, a row of turbine cooling holes in Inconel, or deep holes in hardened tool steel that conventional drilling cannot touch, the right EDM hole drilling machine makes it possible without heat-affected zones, mechanical stress, or tool breakage. Iron Machine Tool distributes a complete range of EDM hole drilling machines from the entry-level H32Z manual unit to the production-capable AD6L CNC submerged system. Steve Brown and the Iron Machine Tool team serve manufacturers across Minnesota, Wisconsin, Iowa, and Illinois. Contact us to discuss your application and get a machine recommendation.
What Is EDM Hole Drilling?
EDM hole drilling (also called fast hole EDM, small hole EDM drilling, or EDM hole popping) is an electrical discharge machining process that uses a rotating tubular electrode typically 0.012" to 0.125" in diameter to erode precise, small-diameter holes through any electrically conductive material. Unlike conventional twist drills, the EDM electrode never makes physical contact with the workpiece. Instead, rapid electrical discharges between the electrode and the material vaporize the metal, while a continuous flow of dielectric fluid flushes away the eroded particles. This non-contact process allows EDM hole drilling to pierce materials that would break a conventional drill in seconds: fully hardened tool steel (60+ HRC), cemented carbide, Inconel, titanium, and other exotic alloys. Holes can be drilled at any angle, to significant depth-to-diameter ratios, and without the burrs, heat-affected zones, or mechanical stress that conventional drilling creates. EDM hole drilling is most commonly used to produce start holes for wire EDM threading, turbine blade and vane cooling holes in aerospace applications, orifices in injection and extrusion dies, and precision holes in medical device components.
How an EDM Hole Popper Works
An EDM hole drilling machine, commonly called a hole popper, uses a rotating tubular electrode and controlled electrical discharge to erode material and burn holes through hardened steel, carbide, and other conductive materials regardless of hardness. Coolant flushes debris from the hole as it forms, and submerged models fully immerse the workpiece for cleaner results on deep or small diameter holes. This process is standard for mold makers needing cooling channels and vent holes that conventional drilling cannot reliably produce.
Need Help Choosing an EDM Hole Drilling Machine?
Talk to Steve Brown about matching the right hole popper to your production volume and hole size requirements.
Choosing the Right EDM Hole Drilling Machine
- H32Z (Manual): Best for low volume shops and simple through hole work.
- SD-530 / SD-750 (CNC): Automatic electrode and guide changers for repeat production runs.
- AD6L (CNC Submerged): Full submersion for the highest precision on deep or micro hole drilling.
H32Z (Manual)
The H32Z is a manual EDM hole drilling machine designed for shops that need fast, accurate small holes without CNC complexity. It drills holes from 0.012" to 0.118" in diameter through hardened metals, carbide, and other conductive materials that conventional drilling cannot penetrate. Ideal for low-volume prototype work, tool and die shops drilling start holes for wire EDM, and applications where a CNC controller is not required. Its straightforward manual operation keeps setup time minimal and cost of entry low.
- Worktable Size (W x D)
23.6” x 11.8” - Travels (X,Y)
13.8” x 9.8” - Electrode Stroke (W-Axis)
13.4” - Worktable Size (W x D)
23.6” x 11.8” - Travels (X,Y)
13.8” x 9.8” - Electrode Stroke (W-Axis)
13.4” - Electrode Diameter Range
.008” ~ 0.124” (optional 0.236”)
SD-530 CNC
The SD-530 is a CNC EDM hole drilling machine combining programmable precision with a compact footprint. Its CNC controller enables repeatable, high-volume hole drilling in hardened steel, carbide, titanium, Inconel, and other conductive metals delivering consistent hole quality without operator intervention between cycles. The SD-530 is well suited for production shops drilling wire EDM start holes, extrusion die orifices, and small cooling holes across medium-scale part runs.
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- Travels (XY)
21.6” x 11.8” - Electrode Travel (W-Axis)
23.6” - Guide Travel (Z-Axis)
14.2”
- Travels (XY)
21.6” x 11.8” - Electrode Travel (W-Axis)
23.6” - Guide Travel (Z-Axis)
14.2” - Distance from Table to Guide
3.6” ~ 17.8” - Electrode Diameter Range
0.012” ~ 0.124” (0.236” optional) - 10 Position Automatic Electrode Changer is Standard
- 4 Position Automation Guide Changer is Standard
- Travels (XY)
SD-750 (CNC)
The SD-750 is a step up from the SD-530 in work envelope capacity, accommodating larger workpieces while maintaining the same CNC precision for repeatable hole drilling in hardened and exotic metals. Where the job calls for consistent, automated hole drilling on parts too large for a compact unit, the SD-750 is the production choice. Applications include aerospace structural components, large mold and die tooling, and industrial-scale wire EDM start hole preparation.
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- Travels (XY)
27.5” x 17.7” - Electrode Travel (W-Axis)
27.6” - Guide Travel (Z-Axis)
14.2”
- Travels (XY)
27.5” x 17.7” - Electrode Travel (W-Axis)
27.6” - Guide Travel (Z-Axis)
14.2” - Distance from Table to Guide
3.6” ~ 17.8” - Electrode Diameter Range
0.012” ~ 0.124” (0.236” optional) - 15 Position Automatic Electrode Changer is Standard
- 4 Position Automation Guide Changer is Standard
- Travels (XY)
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AD6L (CNC) Submerged
The AD6L is Iron Machine Tool's most capable EDM hole drilling machine a fully CNC, submerged-operation unit designed for high-precision, high-production environments. Submerged EDM hole drilling provides superior surface finish, better flushing of eroded material, and more consistent hole geometry compared to non-submerged systems, making the AD6L the right choice for micro hole drilling, aerospace turbine cooling holes, and applications requiring the tightest diameter tolerances. If your application demands the highest accuracy in EDM hole drilling, the AD6L is where the conversation starts.
- Travels (XY)
23.6” x 15.7” - Electrode Travel (W-Axis)
19.7” - Guide Travel (Z-Axis)
13.8”
- Travels (XY)
23.6” x 15.7” - Electrode Travel (W-Axis)
19.7” - Guide Travel (Z-Axis)
13.8” - Distance from Table to Guide
1.2” ~ 15” - Electrode Diameter Range
0.008” ~ 0.124” - 10 or 20 Position Automatic Electrode Changer
- 5 - 20 Position Automation Guide Changer
- Optional 5th or 6th Axis Rotatory or Tilt-Turn Table
EDM Hole Drilling Machine Specifications : At a Glance
| Machine | Electrode Diameter Range | XY Travels | Operation Type | Best For |
| H32Z | 0.008" – 0.124" (+ 0.236" opt.) | 13.8" x 9.8" | Manual | Prototype work, low-volume wire EDM start holes, entry-level capability |
| SD-530 CNC | 0.012" – 0.124" (+ 0.236" opt.) | 21.6" x 11.8" | CNC | Production wire EDM start holes, extrusion die orifices, mid-volume runs |
| SD-750 CNC | 0.012" – 0.124" (+ 0.236" opt.) | 27.5" x 17.7" | CNC | Larger workpieces, aerospace structural components, high-volume CNC hole drilling |
| AD6L CNC Submerged | 0.008" – 0.124" | 23.6" x 15.7" | CNC / Submerged | Micro holes, turbine cooling holes, highest precision / tightest tolerance applications |
How to Choose Your EDM Hole Drilling Machine
- If you need start holes for wire EDM and run low to moderate volume: The H32Z manual is your most cost-effective option. Simple to set up, no CNC complexity, and capable of the small diameter holes wire EDM requires.
- If you run consistent production volumes and need repeatability: The SD-530 or SD-750 CNC machines give you programmable cycle control, reducing operator time and improving hole-to-hole consistency.
- If your application demands the tightest tolerances, submerged operation, or micro-scale holes: The AD6L CNC submerged machine is the right conversation to start. Submerged operation improves flushing, surface finish, and hole geometry in demanding aerospace and medical applications.
- If you are unsure which machine fits your application: Contact Steve Brown at Iron Machine Tool. He has placed EDM hole drilling machines in aerospace, medical device, mold and die, and precision machining environments across the Midwest and can recommend the right machine for your specific hole size, material, and production volume.
- If your application involves cavity sinking, graphite or copper electrode work, or complex 3D geometry: Iron Machine Tool also distributes sinker EDM machines for applications where wire EDM or hole drilling is not the right process.
EDM Hole Drilling Applications
EDM hole drilling machines are used across industries where conventional drilling fails or creates unacceptable results:
- Wire EDM Start Holes: Every wire EDM cut requires a start hole for the wire to thread through. EDM hole drilling is the standard method for drilling these holes in hardened workpieces before wire EDM cutting begins. High-volume shops benefit from CNC EDM hole drilling machines that automate start hole production across multiple parts in a single setup.
- Aerospace Turbine Cooling Holes: Turbine blades, vanes, and combustor components require hundreds of small cooling holes often in Inconel or titanium at precise angles and depths. The non-contact, non-mechanical nature of EDM hole drilling makes it the only viable process for these applications in fully hardened superalloy components.
- Extrusion and Injection Die Orifices: EDM hole drilling produces the precision orifice geometry required in extrusion dies and injection mold gates that cannot be achieved with conventional twist drilling.
- Medical Device Components: Surgical instruments, implant components, and medical device housings often require precision holes in hardened stainless steel, titanium, or cobalt-chrome alloys. EDM hole drilling produces these holes without creating the burrs or heat-affected zones that disqualify conventionally drilled parts.
- Mold and Die Industry: Progressive die sets, blanking dies, and injection molds frequently require small, deep holes for ejector pins, cooling channels, and vent holes that must be drilled through hardened tool steel after heat treatment.
Frequently Asked Questions : EDM Hole Drilling Machines
A: Fast hole EDM is another name for EDM hole drilling, emphasizing its speed advantage over conventional machining of small holes in hard materials. Fast hole EDM machines use a high-speed rotating electrode and aggressive flushing to maximize material removal rate while maintaining hole geometry. CNC fast hole EDM machines further accelerate production by automating the drill cycle across multiple holes or parts.
A: EDM hole drilling is an electrical discharge machining process that uses a rotating tubular electrode to burn precise small-diameter holes through any electrically conductive material. The electrode never contacts the workpiece — electrical sparks erode the material, and dielectric fluid flushes away debris. This allows EDM hole drilling to pierce hardened tool steel, carbide, titanium, Inconel, and other materials that would break a conventional drill.
A: The most common EDM hole drilling applications include:
- Wire EDM start holes : drilling the threading hole through hardened workpieces before wire EDM cutting;
- Aerospace turbine cooling holes : precision holes in Inconel and titanium blades at extreme depth-to-diameter ratios;
- Extrusion and injection die orifices : precision entry holes in hardened dies;
- Medical device components : burr-free holes in titanium and stainless surgical instruments;
- Mold and die ejector pin holes drilled through hardened tool steel after heat treatment.
A: Submerged EDM hole drilling (as in the AD6L) operates with the workpiece fully immersed in dielectric fluid during the drilling cycle. Submerged operation improves debris flushing, produces better surface finish inside the hole, and enables more consistent hole geometry particularly important for micro hole applications, tight-tolerance aerospace holes, and high-aspect-ratio holes where standard flushing cannot remove eroded material effectively.
A: EDM hole drilling works on any electrically conductive material, regardless of hardness. Common materials include: hardened tool steel (D2, H13, P20, M2), cemented carbide, titanium, Inconel 718 and 625, Hastelloy, stainless steel, copper, brass, and aluminum. Unlike twist drills, the EDM hole drilling electrode is not affected by workpiece hardness the process works equally well on soft and fully hardened materials.
A: EDM hole drilling machines typically produce holes from approximately 0.012" (0.3 mm) up to 0.125" (3.0 mm) in diameter, with some systems capable of larger diameters. The minimum achievable hole size depends on the machine model and electrode type. For micro hole drilling applications below 0.012", submerged EDM systems such as the AD6L offer the best results. Verify specific diameter capabilities with Steve Brown at Iron Machine Tool for your application.
A: Manual EDM hole drilling machines (such as the H32Z) require the operator to position and control the drill cycle by hand. They are cost-effective for low-volume work, prototype applications, and shops that only occasionally need start holes. CNC EDM hole drilling machines (SD-530, SD-750, AD6L) are fully programmable they automate the drill cycle, enable multi-hole production runs without operator intervention, and deliver greater hole-to-hole consistency for production environments.
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