Drilling Composite Materials: Best Practices with Diamond Drills & Hole Saws

Composite materials have become the standard in high-performance industries — aerospace, automotive, medical, energy, and beyond. Their unique combinations of strength, weight reduction, and durability make them ideal for advanced manufacturing. But when it comes to drilling composite materials, challenges arise that demand far more than conventional tools and techniques.

At UKAM Industrial Superhard Tools, we specialize in developing diamond core drills and hole saws specifically engineered to overcome the challenges of composite drilling — delivering precision, performance, and longevity you can depend on.


Why Drilling Composites Is So Challenging

Composite materials are engineered from two or more constituent materials with significantly different physical or chemical properties. Common composites include:

  • Carbon fiber reinforced polymers (CFRP)
  • Glass fiber reinforced polymers (GFRP)
  • Kevlar® reinforced materials
  • Phenolic and epoxy laminates
  • Ceramic matrix composites
  • Honeycomb structures and fiber-metal laminates (FMLs)

Each layer in a composite behaves differently under stress, heat, and friction. The result? When drilling with standard tools, issues like delamination, fiber pull-out, burning, splintering, and rapid tool wear are common.

Why Use Diamond Drills and Hole Saws?

Diamond drills and hole saws excel where other tools fail. Their abrasive cutting mechanism, rather than mechanical shearing, allows them to grind through composites with minimal heat, pressure, and vibration. This results in:

✅ Clean, precision holes

✅ Minimal damage to material layers

✅ Extended tool life

✅ Higher feed rates

✅ Consistent performance with minimal maintenance

SMART CUT® Technology for Composite Drilling

UKAM’s SMART CUT® Diamond Drills and Hole Saws are engineered with advanced bond matrix technology that ensures:

  • Faster drilling speeds
  • Reduced chipping and cracking
  • Improved edge quality
  • Cooler operation with proper lubrication
  • Lower total cost per hole

Unlike traditional tooling, SMART CUT® diamond tools are designed for high-speed production, laboratory research, and delicate composites alike.

Choosing the Right Diamond Drill for Composites

When selecting the best drill for your application, consider the following:

1. Tool Design

  • Thin wall core drills: For precision, low-torque applications with reduced material stress.
  • Hole saws: Ideal for drilling larger diameters and through-thickness holes in sandwich panels or structural composites.

2. Bond Type

  • Metal bond: Long-lasting, ideal for harder composite materials and production drilling.
  • Resin bond: Softer cutting action, better for delicate or layered composites with risk of delamination.

3. Grit Size

  • Coarse grit (30–60): For faster cutting, but more aggressive.
  • Fine grit (100–200): For smoother finishes and minimal damage.

Best Practices for Drilling Composite Materials

To get the most out of your diamond tools — and your materials — follow these expert-recommended practices:

✅ Use Coolant or Lubricant

Water-based or synthetic coolants help reduce heat and friction. This prevents resin smearing and thermal damage to the composite matrix. Dry drilling is possible in some cases, but wet drilling is always recommended for high-precision or critical parts.

✅ Use the Correct RPM and Feed Rate

Every material behaves differently. A general starting point for composites is:

  • RPM: 2,000–10,000 (depending on diameter and material)
  • Feed Rate: 1–5 mm/sec for hand-held, 10–30 mm/min for CNC or drill press

Slower, controlled feed minimizes vibration and tearing, especially at hole entry and exit.

✅ Secure the Workpiece

Clamping the material firmly helps reduce vibration and material shift during drilling — major contributors to splintering and delamination.

✅ Exit Support Matters

Place a backup plate beneath the composite material to support the exit side of the drill and avoid breakout damage.

✅ Dress Your Drill Periodically

Dressing re-exposes the diamond grit and maintains cutting performance. UKAM offers dressing sticks and services to extend your tool’s lifespan.

Applications of Diamond Drilling in Composites

Our SMART CUT® diamond drills and hole saws are used in:

  • Aerospace structures (carbon fiber, fiberglass)
  • Wind turbine blades
  • Automotive and EV battery housings
  • Medical imaging housings
  • PCB and semiconductor substrates
  • Defense & ballistic panels
  • Research labs & composite R&D

Whether you're creating clean through-holes or intricate internal cutouts, precision is critical — and diamond tools offer just that.

Custom Diamond Drills for Composite Applications

No one composite application is the same — and we understand that. UKAM Industrial offers custom diamond drill and hole saw manufacturing, tailored to:

  • Specific diameters
  • Wall thickness
  • Bond types
  • Lengths and arbor types
  • Grit and geometry

If you're working with a rare or difficult composite, or need tooling for a specialized setup, our technical experts can engineer a drill that matches your specs perfectly.

Final Thoughts: Precision Drilling Starts with the Right Tool

Composite materials are here to stay — and so is the need for drilling them with accuracy and efficiency. The wrong tool can cost you time, materials, and money. But the right diamond drill or hole saw, optimized for your composite material and application, can completely transform your workflow.

At UKAM, we’ve helped thousands of engineers, machinists, researchers, and fabricators drill composites with precision and repeatability. Let us help you too.

Have a unique composite or application? Contact our technical team for expert recommendations or custom tooling.

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