Small hole Drilling EDM (also known as "Small Hole EDM" or "Hole Popping") is a specialized component of Electrical Discharge Machining (see below). This process can drill holes in any conductive material (regardless of hardness or toughness) more quickly and accurately than conventional drilling. The process is burr free and very accurate. It can produce holes from 0.002" to 0.125" in diameter and typically ranging in size to 12.0" high x 20.5" wide x 24.0" long.

Electrical discharge machining (EDM), sometimes referred to as spark machining, is a nontraditional method of removing metal by a series of rapidly recurring electrical discharges between an electrode (the cutting tool) and the workpiece in the presence of a dielectric field. The ensuing minute metal chips are removed by melting and vaporization, and are washed away by the continuously flushing dielectric fluid. EDM can cut materials regardless of their hardness or toughness, but is limited to the machining of electrically conductive workpiece materials. It can handle tough situations like hardened materials that cannot be conventionally machined, as well as difficult to cut carbide and heat treated workpieces.

Many holes are either not cost effective or impossible to drill using conventional means. Small hole drilling is a huge technological problem: problems arise with chip transport and heat dissipation. The EDM method enables even the smallest holes to be manufactured. Other non-conventional methods like laser and electron beam can be used to drill small holes, but these processes are typically too expensive for common use. EDM is the best choice for machining electric conductive materials, especially for holes of uncommon shapes.

EDM Small Hole Drilling is used to drill through any electrically conductive material efficiently and burr-free. Applications include: cooling holes for workpieces in high temperature applications, holes for ejector pins, core pins, aircraft fasteners, and turbine blade vent holes. Wire safety holes can be put in parts where the hole goes through a slanted or curved surface and conventional drilling would be very difficult. CNC controls allow hole patterns with close locational tolerances.