15.10.2026

MAPAL redefines deep drilling in aluminium

Second-generation MEGA-Deep-Drill-Alu for process-reliable machining of large drilling depths combined with high material flexibility

With the second generation of the MEGA-Deep-Drill-Alu, MAPAL is setting new standards in aluminium machining. The new tool is designed to reliably master the typical challenges associated with large drilling depths: stable processes, reliable chip removal and high feed rates.

The image shows three variants of MAPAL’s new MEGA-Deep-Drill-Alu deep-hole drill for machining aluminium materials.

It is based on a newly developed overall concept comprising cutting edge geometry, cooling and cutting material. The new geometry includes a wide range of applications, from wrought alloys through to cast alloys with high silicon content. The straight main cutting edge ensures smooth, low-vibration processes and reduces macroscopic flaws and burr formation, particularly in demanding applications, such as cross bores or angled exits. Double point thinning and optimised chip flutes ensure improved chip removal. The adapted core diameter profile also increases tool stability, thereby enhancing process reliability at large drilling depths.

Another key factor for process reliability is precise tool guidance over the entire drilling depth. Four guide margins stabilise the process even with cross bores or angled exits, ensuring reliable machining conditions even at high feed rates.

The image shows the new MEGA-Deep-Drill-Alu deep drill for aluminium materials from MAPAL during machining in a machine tool. — Stable up to 40×D: The MEGA-Deep-Drill-Alu demonstrates reliable guiding behaviour even with large length-to-diameter ratios and offers high process reliability. ©MAPAL

Efficient cooling as a differentiating feature

A key differentiating feature is the cooling system: newly defined cooling channels, enlarged by 20 percent, direct a higher volume of coolant to the main cutting edge and cutting edge corners. Compared with other solutions on the market with lower coolant volumes, they significantly improve wear behaviour, tool life and process stability. At the same time, stability, fracture strength and, therefore, process reliability are maintained. The advantage of this improved cooling behaviour is particularly relevant at large depths and in applications with minimum quantity lubrication.

High flexibility through a coordinated cutting material concept

The performance of the second-generation MEGA-Deep-Drill-Alu is significantly enhanced by the coordinated cutting material concept. The basis is an uncoated design with ultra-finely ground chip flutes. This enables process-reliable machining of different aluminium materials and already offers a broad range of applications. Two configurable head coatings are available for even more targeted adaptation to the silicon content of the aluminium alloy and the coolant/lubricant strategy. This means the MEGA-Deep-Drill-Alu covers a broad spectrum of aluminium cutting materials and enables stable processes in different applications.

Proven in practice, presented at AMB

The new second-generation MEGA-Deep-Drill-Alu from MAPAL offers large drilling depths, high process reliability and flexible adaptation to different aluminium materials, all in one integrated tool concept. Extensive trials with end-users confirm the great potential of the new generation. For example, the MEGA-Deep-Drill-Alu achieved feeds of up to 0.4 mm per revolution and tool lives of up to 3.2 kilometres.

The new deep drill was particularly developed for applications in the automotive industry and general machining. It is available in length versions from 15×D to 40×D and, depending on the respective length, in diameters from 3 to 16 mm.

Find out more about the 2026/2027 innovations