Flowdrilling is a process that uses a solid carbide bit to form a hole in thin walled material.  The bit is spun and pushed against the part to generate heat at the tip of the bit.  The heat softens the metal and the constant pressure begins to form the metal around the bit.  After the process is completed, a formed bushing is left that can be tapped with a form tap.

For a demonstration visit www.flowdrill.com.