Additional customisation from BRM in a variety of shapes is also possible to meet the requirements of non-traditional applications. This includes spherical-end configurations, stepped or multi-diameter configurations for double diameters and counter-bores, tapered or cone shapes, segmented shapes, or combining Flex-Hone globules with other filament materials.

Whether you choose an electric benchtop sharpener or a grinder attachment, there’s a solution for your dull drill bits. Your drill bits will last much longer if you choose the best drill bit sharpener for your needs from this guide. Each of the top picks below was selected after an in-depth review of the market and thorough product vetting.

Available in sizes ranging from very small diameter hones (4mm) to those up to 36 inches or more in diameter (a size appropriate for large engine cylinder bores), these deburring tools can be custom designed to the size, shape and abrasive grit to fit any application’s needs.

Despite the challenges, the removal of burrs from the production process is an absolute must for the high quality, precision parts required in aerospace. In many applications, cross-drilled holes act as conduits for fluids, lubricants and gases. Failing to remove burrs can cause blockage of these critical passages or create turbulence in the flow. Burrs can also lead to part misalignments, affect dimensional tolerances, and limit the overall efficiency of machined components. “Getting rid of burrs is really important because if there is any loose material that gets dislodged when the product is in use, it can cause major problems,” says Anthony Scott, lead machinist at Orange Vise Company, a manufacturer of machine vices and quick change fixturing components used throughout aerospace. Although there are many techniques for deburring internal passages at cross-holes, the majority require sending out parts or investing in equipment to complete the work in-house that can cost tens of thousands of dollars. These options, which include thermal, abrasive flow, electrochemical, and high-pressure water, effectively remove excess material but they also build time into the manufacturing process and add to costs. Before and after deburring The more ideal option, however, for many aerospace operations is to integrate deburring into the automated process with a simple, effective crosshole deburring tool such as the Flex-Hone from Brush Research Manufacturing (BRM). By doing so, operators can speed up the manufacturing process and ensure uniform quality for precision parts. According to Scott, flexible hones are ideal because it is a cost-effective solution to smooth edges and produce a blended radius for crosshole deburring. “It is really about accessibility, because there aren’t many tools that can do this,” he says. “Whether it is internal grooves or multiple cross-holes, there is really no way to reach those areas with any other tool we have found.” For engineers in aerospace manufacturing, the ball-style hone is a highly specialised abrasive tool that is instantly recognisable by its appearance. Characterised by the small, abrasive globules that are permanently mounted to flexible filaments, the product is a flexible, low cost tool utilised for sophisticated surfacing, deburring and edge-blending. Available in sizes ranging from very small diameter hones (4mm) to those up to 36 inches or more in diameter (a size appropriate for large engine cylinder bores), these deburring tools can be custom designed to the size, shape and abrasive grit to fit any application’s needs. “I use the Flex-Hone quite a bit working in aerospace,” explains Ken Spaulding of Zodiac Engineering, a contract manufacturer in California. “We do a lot of parts that involve tubes with multiple crossholes and slots. Getting inside there to reach the burrs, particularly if the walls are thick, is extremely difficult.” Spaulding particularly appreciates how the flexible hone’s abrasive globules each have independent suspension that is self-centring, self-aligning to the bore, and self-compensating for wear, all of which facilitate close-tolerance finishing work. “The hone conforms to whatever you are working with, even if it’s irregular,” he says. “For example, if the back side of the part is not flat or not on consistent level plane in Z, the tool is flexible enough to still remove any burrs.” For best results, the deburring tool is typically rotated into the main bore into which the crossholes break. After a few clockwise strokes, the tool is removed and the spindle reversed to rotate and stroke the flexible hone in a counter-clockwise direction for a few more strokes. The forward and reverse rotation creates a symmetrical deburring pattern. Coolant should be used to keep metal cuttings and deburred metal in suspension. According to Orange Vise’s Scott, although the Flex-Hone is often used with automated production equipment it can also be used for secondary deburring options offline as needed. “The tool can be used in CNC machines and also with a cordless drill,” says Scott. “So, if you manage to deburr 90% of the holes in a machine, but have a few left you can’t access easily, you can use it with a handheld drill and maintain the uniformity in surface finish and process.” Additional customisation from BRM in a variety of shapes is also possible to meet the requirements of non-traditional applications. This includes spherical-end configurations, stepped or multi-diameter configurations for double diameters and counter-bores, tapered or cone shapes, segmented shapes, or combining Flex-Hone globules with other filament materials. www.brushresearch.com

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You will also want to look for a sharpener that can handle your smaller bits. While these bits are rarely expensive (depending on the material), they dull quickly and lose their performance right away. Instead, keeping one of the best drill bit sharpeners on hand will allow you to put a quick edge on a bit as small as 3/32-inch.

We narrowed our research to include drill bit sharpeners that have only a select number of angles to drill at or a range of adjustable angles—though the extra adjustments can make it tricky to operate as well. Each selection on our list has online videos that can be used to help users learn how to properly use the sharpener. Finally, we included recommendations that had a number of different price points and levels of professional quality for both hobbyists and professionals.

If you’re looking for an electric benchtop drill sharpener that allows you to get the most out of your old drill bits, the Drill Doctor 750X is worth a look. Users can adjust the 750X for any angle between 115 and 140 degrees, which means this sharpener can handle almost any angle. It will also create an edge on the end of the bit called a “split” bit, which creates a sharp point to drill accurate holes.

Finding a drill bit sharpener that works with your drill bits of choice is important. For most homeowners, a standard drill bit sharpener will accommodate most of the bits in your workshop. These bits usually consist of steel or cobalt, and standard grinding wheels will sharpen them with ease.

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These options, which include thermal, abrasive flow, electrochemical, and high-pressure water, effectively remove excess material but they also build time into the manufacturing process and add to costs.

These recommendations have a range of capabilities to sharpen drill bits of varying sizes. Some drill bit sharpeners can accommodate bits as small as ³⁄₃₂ of an inch or as large as 1½ inches. Since users have unique needs, this list includes sharpeners that offer a solution for almost every commonly used drill bit.

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Purchasing a drill bit sharpener that can handle all of the bits you commonly use should be a priority. While almost all sharpeners can handle small to mid-range bits, only certain models can handle the big stuff. Bits over 1/2-inch are expensive, so make sure that your sharpener can handle them.

There are two popular power sources for sharpening your drill bits; plug-in electric and drill-powered (which may be electric or battery).

Drill bits aren’t cheap, but neither are sharpeners. If you’re not going through bits constantly, it may be useful to purchase an inexpensive, drill-powered sharpener to put an edge on your bits. You’ll find that they do a decent job, and if you’re not drilling precision holes, they’ll grind a useful edge.

Characterised by the small, abrasive globules that are permanently mounted to flexible filaments, the product is a flexible, low cost tool utilised for sophisticated surfacing, deburring and edge-blending.

“Getting rid of burrs is really important because if there is any loose material that gets dislodged when the product is in use, it can cause major problems,” says Anthony Scott, lead machinist at Orange Vise Company, a manufacturer of machine vices and quick change fixturing components used throughout aerospace.

According to Scott, flexible hones are ideal because it is a cost-effective solution to smooth edges and produce a blended radius for crosshole deburring.

If you purchase high-end carbide drill bits, then a standard grinding wheel won’t work. Carbide is extremely hard and requires a diamond wheel to sharpen correctly. If you keep carbide bits on hand, look for a sharpener that comes with diamond wheels. Or, purchase a bench grinder jig that you can set up with a diamond grinder wheel.

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You can, but they’ll never be quite as effective again. Titanium bits have a coating that the grinding wheel will remove when sharpening. That’s not to say the bits are no good; they just won’t have the hard coating that makes them so useful.

For folks who already have a bench grinder, the General Tools 825 drill grinding attachment is an affordable way to take care of a pile of dull drill bits. This jig bolts to the worktop and uses the side of a grinding wheel to create sharp edges on old drill bits.

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Sharpening drill bits is all about saving money, and the Drill Doctor DD350X will do that time and time again. This low-priced drill bit sharpener allows users to put fresh 118-degree grinds on old, dull drill bits. It can handle any drill bit size between 3/32 inch and ½ inch, and it comes with a diamond wheel to help users get the most out of their sharpener.

Various types of drill bits use differently-angled cutting edges at their points. Bits reserved for wood have aggressive cutting edges to allow them to get through the material quickly. Bits for metal have flatter angles, allowing them to take off smaller bits at a time without overheating or chipping the bit.

The Drill Doctor 750X will sharpen drill bits as small as 3/32 inch and up to ¾ inch, making it versatile for any drill bit a DIYer is likely to use. It also comes with a diamond wheel, so grinding fresh edges on carbide bits is not a problem.

“I use the Flex-Hone quite a bit working in aerospace,” explains Ken Spaulding of Zodiac Engineering, a contract manufacturer in California. “We do a lot of parts that involve tubes with multiple crossholes and slots. Getting inside there to reach the burrs, particularly if the walls are thick, is extremely difficult.”

Each sharpener is different, but you, or the jig, hold the bit at a specific angle relative to a grinding wheel. The grinding wheel removes metal from the tip of the drill bit until the edge is sharp.

Those shopping for a bench grinder attachment that will help take expensive drill bits from dull to unbelievably sharp will want to check out the Tormek DBS-22. This drill bit sharpener allows users to adjust the angle from 90 degrees to 150 degrees and features an adjustable split angle.

“It is really about accessibility, because there aren’t many tools that can do this,” he says. “Whether it is internal grooves or multiple cross-holes, there is really no way to reach those areas with any other tool we have found.”

“The tool can be used in CNC machines and also with a cordless drill,” says Scott. “So, if you manage to deburr 90% of the holes in a machine, but have a few left you can’t access easily, you can use it with a handheld drill and maintain the uniformity in surface finish and process.”

Prototypes of the US Air Force's sixth generation fighter jet, which is meant to be deployed in 2030, have already flown in secret.

There’s a lot that goes into shopping for one of these tools, but all the machines on our list below are worth considering. They’re easy to use, accurate, and can keep you from having to throw out the best (and occasionally expensive) drill bits in your collection.

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While you can sharpen every drill bit to one consistent angle, certain styles of bits work best at specific angles. It’s better to have a sharpener that you can adjust to the drill bit. Standard angles are between 118 and 135 degrees, so look for a sharpener that allows you to switch between the two for the best versatility.

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If you already own a bench grinder, an attachment may be the best route to go. They’re far less expensive than a benchtop model, and you can achieve the same angles. They take a little longer to set up, but you won’t sacrifice any quality once you do.

The sharpener comes with a diamond grinding wheel to handle high-speed steel, cobalt, or carbide bits with ease. It can also “split” the end of the drill bit, producing a more accurately drilled hole. It can sharpen drill bits between 3/32 inch and ½ inch to handle most drill bits in a standard set.

Although there are many techniques for deburring internal passages at cross-holes, the majority require sending out parts or investing in equipment to complete the work in-house that can cost tens of thousands of dollars.

DIYers and professionals who need a portable drill bit sharpener will want to take a good look at the Drill Doctor X2 sharpener. This versatile and compact model weighs just 3 pounds and is small enough to fit inside a tool box or case. Made with an electric plug-in design, this Drill Doctor can be used anywhere it is needed and can sharpen drill bits, tools, knives, scissors, and more.

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For engineers in aerospace manufacturing, the ball-style hone is a highly specialised abrasive tool that is instantly recognisable by its appearance.

As for user-friendliness, this Wen also has a built-in work light, a quenching tray, dual eye guards, a large and easy-to-read on/off switch, an 80-grit wheel, and a 36-grit wheel, making it safe and ideal for drill bit sharpening as well as cleaning and deburring. Though this model has a steep price tag and isn’t the most portable option at 41 pounds, it offers durability and effectiveness for long-term use.

If you wish that you knew about drill bit sharpeners a long time ago, you’re not alone. Many have wasted money on new bits when the old ones become dull. Now that you do know a bit about the best drill bit sharpeners, you might have some more questions. Below are the most frequently asked questions and answers about drill bit sharpeners. If you don’t find your answer here, contact the sharpener’s manufacturer.

Drill bits aren’t cheap, but they do seem to dull quickly. Whether you’re drilling through dense hardwood or hardened steel, some drill bits seem to lose their edge within minutes of coming out of the package.

Sharp bits drill faster and more accurately. When the tip of a drill bit becomes dull, it won’t dig in exactly where you’d like it and will also drill crooked or elongated holes. A sharp bit will bore straight down and create a perfectly round hole in almost any material. Having your own drill bit sharpener will allow you to keep your bits in top condition.

The more ideal option, however, for many aerospace operations is to integrate deburring into the automated process with a simple, effective crosshole deburring tool such as the Flex-Hone from Brush Research Manufacturing (BRM). By doing so, operators can speed up the manufacturing process and ensure uniform quality for precision parts.

Let’s get to the point: There are some things you need to know when shopping for the best drill bit sharpener. Not all models have the same capabilities or uses, so you need to be sure the one you choose will get the job done. Here are some factors worth considering.

The sharpener will work for bits between ⅛ inch and ¾ inch and is adjustable for many different drill point angles. It has several adjustments, one of which adjusts the height of the drill bit. This adjustment allows users to creep up on the perfect angle slowly for maximum accuracy. To create a perfectly centered point, simply roll the bit over between every pass.

Since it doesn’t create split points, Drill Doctor made it more compact so it can sit on a shelf without getting in the way. There are no angle adjustments, which makes this a great tool for those looking for a simple, straightforward drill bit sharpener.

The Work Sharp knife and tool sharpener can bail you out in a pinch. While not specifically a drill bit sharpener, this model can put a quick edge on a drill bit and get you back to work in a hurry. It features five belts of various coarse levels, allowing users to put a serviceable edge on a high-speed steel or cobalt drill bit.

The result is a completely custom drill bit that’s both incredibly accurate and fast cutting. It can handle drill bits as small as ⅛ inch and as large as ⅞ inch, providing an excellent range to work within. Use this jig with any type of drill bit, but use a diamond grinding wheel for carbide bits.

According to Orange Vise’s Scott, although the Flex-Hone is often used with automated production equipment it can also be used for secondary deburring options offline as needed.

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If you’re looking for a foolproof drill bit sharpener, the DD500X from Drill Doctor is as close as possible. This drill bit sharpener has two angle presets of 118 and 135 degrees. These presets allow users to choose the right angle for their drill bit type without worrying if they’re off a degree or two.

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This small but mighty model offers side-by-side sharpening and is made with a dual-speed motor, ½-inch chuck, a 20-degree knife sharpening guide and hone, and a 118-degree drill bit sharpening port. For added convenience, this Drill Doctor also comes with a replacement abrasive disc and a user manual.

For best results, the deburring tool is typically rotated into the main bore into which the crossholes break. After a few clockwise strokes, the tool is removed and the spindle reversed to rotate and stroke the flexible hone in a counter-clockwise direction for a few more strokes.

If ease of operation is important, you should consider purchasing an electric benchtop model. These are the most foolproof of the drill sharpener designs, and they will allow you to put a sharp edge on a drill bit in no time at all.

Those who are experienced and comfortable using bench grinders should feel right at home with this model from Wen. Built for versatility and effectiveness, this drill bit sharpener has a 5-amp variable-speed motor that operates between 2,000 and 3,450 revolutions per minute for sharpening virtually any drill bit size.

All bits are worth sharpening if you already have a sharpener. However, it’s not worth buying a sharpener to put an edge on a 1/8-inch steel drill bit.

Despite the challenges, the removal of burrs from the production process is an absolute must for the high quality, precision parts required in aerospace. In many applications, cross-drilled holes act as conduits for fluids, lubricants and gases. Failing to remove burrs can cause blockage of these critical passages or create turbulence in the flow. Burrs can also lead to part misalignments, affect dimensional tolerances, and limit the overall efficiency of machined components.

If you’re continually working in your home shop or on a job site, having your own drill bit sharpener can save you quite a bit of money. Instead of throwing your old bits out, you can grind a new edge on the spot, or place them to the side and spend an hour grinding a whole set until they’re like new.

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“The hone conforms to whatever you are working with, even if it’s irregular,” he says. “For example, if the back side of the part is not flat or not on consistent level plane in Z, the tool is flexible enough to still remove any burrs.”

Though users may not be able to replicate the exact angle by hand, they’ll come close enough to drill effectively on larger drill bits. It will also handle all knife and scissor sharpening needs, as well as chisels and other cutting tools, though carbide bits are probably too much for this tool. It weighs just 53.6 ounces and is comparatively small, making it perfect for professionals and DIYers to transport.

The forward and reverse rotation creates a symmetrical deburring pattern. Coolant should be used to keep metal cuttings and deburred metal in suspension.

Instead of throwing dull drill bits in the trash, you can restore their cutting edge with the best drill bit sharpener. These tools can help put a sharp point on an older drill bit, grinding the tip at the perfect angle. The result is a fast-drilling, clean-cutting drill bit that works as well, if not better, than new.

Spaulding particularly appreciates how the flexible hone’s abrasive globules each have independent suspension that is self-centring, self-aligning to the bore, and self-compensating for wear, all of which facilitate close-tolerance finishing work.

Drill bit sharpeners can make using drill bits safer. If you’re drilling with a dull bit, you’ll have to use more force to make any progress. A smaller bit can easily snap under pressure, which sometimes sends pieces of drill bit flying. While you should always wear safety glasses, flying bits of metal are never safe. A sharpener will help ensure that you don’t need to put much power behind the bit.