E-Drill: Precision Fastener Removal for F-15 Readiness and DOD-Wide Impact

Reliability Improvement

Problem Statement:  USAF F-15 depot maintenance faces critical challenges during wing and structural teardowns, where traditional drilling to remove high-strength fasteners (e.g., titanium, nickel alloys) frequently damages holes.  These mishaps cause costly repairs, extend aircraft downtime by days, increase foreign object debris (FOD) risks, and demand intensive technician effort, leading to repetitive strain injuries.  In high-tempo operations or contested environments, these delays jeopardize aircraft readiness, inflate sustainment costs, and strain limited depot resources, undermining mission agility, and operational effectiveness.  

Description of the Innovation Solution:  The E-Drill is a patented, hand-held electro-discharge machining (EDM) tool from Perfect Point EDM, that radically transforms fastener removal.  It employs spark erosion with a high-flow water bath for cooling and debris flushing, cutting through fastener heads or tails in seconds.  User-friendly fixtures ensure precise alignment, preventing structural damage.  Compact, portable, and requiring no specialized infrastructure, the E-Drill is optimized for F-15 depot and field maintenance, enabling rapid, damage-free operations in diverse environments. 

Benefits to the DOD:  Authorized for limited use on F-15 wings in non-critical areas, the E-Drill delivered immediate impact: reducing fastener removal time by 90% (seconds vs. minutes), nearly eliminating hole damage, minimizing FOD risks, and easing technician physical strain, enhancing safety and morale.  In F-15 depot trials, it reduced man-hours and repair costs, saving an estimated $1M annually for a single depot.  Scalable across DOD sustainment, with millions of fasteners removed daily across platforms like B-52, B-1, and F-18, the E-Drill could revolutionize this overlooked process, potentially saving $MM yearly enterprise-wide by boosting readiness, cutting downtime, and reducing costs.  Its agility supports DOD's push for efficient, resilient sustainment in contested logistics scenarios. 

Innovation Challenges:  Challenges include ensuring precise alignment to avoid minor EDM marks (mitigated by enhanced fixtures and streamlined training protocols) and integrating the E-Drill into existing maintenance workflows.  Further testing and analysis is required for adoption of the technology on fatigue critical structure. 

Technical Maturity/Demonstration Results:  TRL-9: The E-Drill is fully commercialized and proven in F-15 depot operations.  Trials demonstrated 90%-time savings per fastener, meaningfully reduced instances of damage, and substantial cost reductions.  The USAF F-15 program is deploying 10 E-Drill systems in 2025, establishing benchmarks for DOD-wide adoption.