meatball starlite 1111 Lancaster Avenue
P.O. Box 990
Rosemont, PA 19010-0911, USA
phone: 610-527-1300
or 800-727-1022
fax: 610-527-4463
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starlite designs

Specific Tools for Specific Tasks

Since 1945, Starlite® Industries in Rosemont, PA, has been manufacturing diamond and carbide rotary tools designed to drill, mill, and cut fiber reinforced polymers (FRPs), composites, and other highly-abrasive materials. The actual material to be cut or the amount of machining to be done will dictate the type or design of the tooling to best accomplish the task at hand.

Starlite® manufactures both "Plated" and "Brazed B Bond" diamond tooling for fiberglass and composite applications, which are primarily used for controlled grinding away of material from the work piece. Both types of tooling are similar, in that they both permanently attach diamond to the tool surface. However, Starlite® "Brazed B Bond" tooling, unlike traditionally plated tooling, is "Bonded" so that it has the maximum protrusion at the tool surface with an atomic bond to the brazed alloy, providing utmost diamond retention and no diamond pull out. Both plated and Brazed tooling are available in a variety of designs, including routers, hole saws, countesinks, cut off wheels, and form wheels.

Because of today's technology and modern materials, it has never been more important to match the tool to the task. Using the wrong tool in the right material can not only damage the workpiece but also the tool. Following is a brief explanation of Starlite's® tool to material match ups.

. When routing most non-metallic composites like graphite fiberglass, phenolics, or ceramics, Starlite's "Brazed B Bond" routers can be used for wet or dry grinding. Routing can be accomplished virtually fuzz-free with either Brazed B-Bond diamond routers (run wet or dry) or a "Starbide" solid carbide router.

Starlite's Starbide Routers, with a chisel point design, cut clean and smooth. Polycrystalline Routers also provide a very clean cut, and because they can be resharpened, they give a longer life and reduced cost.

Drilling, Hole Cutting
. For drilling small holes in composites, we make solid carbide drills with specific geometry for precise fuzz-free holes.

When working with graphite composites, we recommend our patented dagger drill from 2.4 mm diameter.

In Kevlar reinforced composite, we find our Brad Point Drill does the best job shearing the Kevlar fiber. The twin Brad points shear the fibers for the cleanest of holes.
The best hold and tightest tolerance hole in graphite is obtained with our drill reamer. For larger holes in composites, our diamond hole saw does a superior job providing a low cost solution to large hole drilling. Starlite's diamond hole saws are available with or without cutting pilots, starting at 6.35 mm and up.

Counter Sinking

. The traditional tool for counter-sinking or counter boring composites has been solid carbide with various lip and rake designs for shearing the fibers embedded within the polymer.

Plated and "Brazed B Bond" coated diamond tools are also very popular as well as economical when comparing the cost and life of the tool. Although initially more expensive, our polycrystalline one-flute or two-flute design is also very popular. The polycrystalline countersinks provide exceptionally clean cuts and, because they can be resharpened, long tool life.
. Trimming operations are best accomplished  with either mounted or unmounted diamond coated wheels. Diamond wheels last much longer than carbide saws and are considerably more economical. 

For further information, please see our Catalog #C00120 for Rotary Tooling Diamond and Carbide, designed to drill, trim, and rout today's composite materials.

The following are registered trademarks of Starlite Industries, Inc.: Magnicon, Starlite, Starflite, Starbond, Starbide, Starpax, and Starpad.

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