Cross-drilled hole deburring

Where two bores meet is where the burr hides, and where it matters most.

The problem with an intersection

When a second bore breaks through the wall of the first, the cutter exits into open space and leaves a burr on the far side of the intersection — inside the part, where nothing reaches it and nothing sees it.

On a manifold with a dozen ports there may be twenty or more of these. Each one is a separate operation, in a different orientation, on a feature that is only visible with the right light and the right magnification.

Removing the burr without touching the bore

The constraint is that the bore itself is usually a controlled dimension. Whatever removes the burr must not open the hole, taper the entry, or leave a radius the print does not call for.

That is why this work is done by hand and verified under magnification rather than run through a process that treats every edge the same. The tool is chosen per material and per geometry — files, blades, pencil grinders, rotary burrs, abrasive wheels.

Parts this applies to

Manifolds, valve bodies, hydraulic fittings, spools and sleeves — anything with intersecting bores or internal fluid passages. Materials we work in include stainless, aluminium, titanium, Inconel, brass, copper, Invar, carbon steel and most plastics.

Lot sizes run from a single prototype piece to fifty thousand, on the same controlled process.