With an innovative drill for CFRP, MAPAL significantly increases tool life and cutting speeds when machining the demanding material, which plays an important role especially in aerospace. The highlight of the new MEGA-Drill-Composite-MD-EdgePro: The tool sharpens itself while drilling.
Multidirectional CFRP layers as a special challenge
Among several possible arrangements of the fibers when bonding the carbon fiber fabric, the multidirectional layers of the composite material pose the greatest challenge in machining. For this reason, they are processed with specially designed tools with specific characteristics. Very sharp tools are required for clean cuts, but their cutting edges are also correspondingly sensitive to wear. Therefore, the drills are usually coated with CVD diamond. However, the coatings increase the cutting edge radius, which negatively affects the cutting properties. The edge is not as sharp as it ideally should be for this machining to produce clean holes without delamination at the entry and exit points.
EdgePro technology for maximum cutting edge sharpness
At this point, MAPAL has literally sharpened with a new technology and presents a drill at AMB 2026 that elevates the machining of multidirectional CFRP materials to a new performance level: In the new EdgePro technology, the main cutting edge is sharpened at the first clearance surface using a laser. What remains is a maximally sharp edge for flawless CFRP drilling without fiber tearing. With its good cutting properties, the EdgePro can also be used for very thin-walled components. The cutting edge generates less cutting pressure, thus preventing springback and bending of the component. For self-centering pilot drilling with high dimensional accuracy and positional accuracy of the hole, the tip is designed with a 90° angle.
Structural features for quality and process reliability
The cutting edge of the new MEGA-Drill-Composite-MD-EdgePro has also been redesigned and is significantly more stable compared to the predecessor tool. This results in less delamination even after longer process applications, contributing to high dimensional accuracy of the hole and better surface quality. In the multidirectional (MD) version of the CFRP, the fibers often realign when the drill is pulled out. An integrated fibrecatcher separates these remnants and contributes to clean drilling quality. For the MEGA-Drill-Composite-MD-EdgePro, MAPAL uses the newly developed CVD diamond coating HC611, which ensures low thermal stress and long tool life even with abrasive materials. In addition to high drilling quality and process reliability, the new drill also scores with higher possible operating parameters. Thus, the MEGA-Drill-Composite-MD-EdgePro can be used with at least 50 percent higher cutting speed compared to conventional CFRP drills.
Self-sharpening effect increases tool life at consistently high quality
A significant advantage of the new MAPAL drill arises during use. Because: It features a so-called self-sharpening effect, which ensures consistently high drilling quality and process reliability in series production throughout the process. Thus, tool life is extended by at least 50 percent.
Developed for demanding CFRP applications
MAPAL offers the new drill tools in the diameter range of 3 to 12 mm; larger holes are usually milled. The drills are used wherever CFRP needs to be machined. Applications can be found in the wind power industry, general industry, sports, and leisure. However, the clear target group for MAPAL is aerospace, where the highest demands are placed on the quality of the holes and the use of the tools in series production quickly pays off. In this area, the first EdgePro tools are already in use. Customer feedback is overwhelmingly positive. In practical use, both the promised increase in cutting values and the stated tool life have been exceeded.
With the self-sharpening drill, MAPAL has a clear unique selling proposition in the market. A comparable principle can be found in nature: The teeth of the beaver also continuously sharpen themselves while gnawing. In reference to this, MAPAL refers to the beaver tooth effect with the EdgePro.
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