What is Formdrill .... Thermal drilling is a process that uses friction to produce bushings in metal tubing and flat stock.  The combined rotational and downward force of our special Thermal Drilling tool bit creates frictional heat. Temperatures can reach 900 C for the tool, and 700 C for the work piece.  The material is transformed into a "super-plastic" state, allowing the tool to displace material and form a bushing. The height of the bushing is roughly 3 to 4 times the original metal thickness. See picture  These bushings are ideal for threaded applications, as the number and strength of threads is significantly increased. It is an excellent alternative to weld nuts or threaded inserts. The bushing can also be used as a support hole for welded, soldered or brazed connections as well as for a load-bearing surface. The Thermal Drilling System can be used in most ferrous and non-ferrous metals including mild steel, stainless steel, copper, brass and aluminium, with material thickness up to 12 mm. In general, all malleable materials can be thermal drilled. Standard drills are available in any size up to 25.4 mm. diameter. Larger drill sizes are available on request. No special equipment is required. A standard drill press, milling machine or CNC machining center is suitable. Thermal Drilling is also ideal for automation because it is a chipless process, produces accurate holes, and has a long tool life.  Thermal Drilling is also well suited for short run or prototype work because of its ease of use.  There is absolutely no cutting involved during the creation of the hole. See video