Electromagnetic Dent Removal

The Electromagnetic Dent Remover (EDR) works on any electrically conductive material. Though it does utilize magnetic fields to remove dents, the EDR does not rely on the material being worked on to be ferromagnetic. In fact, a non-magnetic metal such as aluminum is more amenable to the EDR process than ferromagnetic metals such as iron or steels because of its superior electrical conductivity. Thus, aluminum skinned aircraft are ideal candidates for the EDR process.

The EDR employs a highly sophisticated power supply and electromagnet to create a changing magnetic field. This induces an electrical current into the work-piece (e.g. dented aluminum aircraft panel). At just the right moment the field is rapidly reduced in strength. This sudden reduction in field strength creates a force in the work-piece that pushes it outward, much as a hammer blow from behind would do.

Usually a series of pulls is required to correct each dent. This process typically does not damage paint. Properly applied, it leaves no footprint, does not affect avionics, and can be used on a fueled aircraft. The EDR is especially useful in repairing dents in metal core honeycomb and on panels where access to the rear side of the panel is limited or nonexistent.

Even in situations where access to the rear side of the panel may be possible, economic advantages of the EDR process can be substantial due to saved time and labor. Consider for example hail damage in the top wing surface of a large airplane. While pushing the dents out from inside may be possible depending on the location, doing so could necessitate removing all fuel, some aircraft disassembly, possible tank bladder removal, reassembly, testing, and refueling.

Obviously, if the damage can be corrected by the EDR process in a matter of a few minutes to a few hours as opposed to days or weeks the savings can be huge, not only in terms of labor to make the repair but also by minimizing downtime of the airplane.

Specifications

  • Power Supply Dimensions: 1m x 1m x 2.1m (40"x40"x82")
  • Power Supply Weight: 700kg (1,550lbs)
  • Actuator/Work Coil Weight: 11kg (24lbs)
  • Power Requirement: 120VAC, 20A, 60Hz (grounded neutral)
    • New systems can be designed to customer requirements
Requirements

Supplementary Equipment Requirements

A forklift capable of lifting the EDR power supply and supporting it within 20ft (6 meters) of the area to be repaired and a man-lift or suitable scaffold for the operator to stand on may be required, especially when working on larger aircraft.

Environment

The EDR should be used only in dry locations and should be protected from weather at all times. To prevent overheating of internal components, it should be kept out of direct sunlight when in use. Damp or dusty environments should also be avoided.

Power Requirements

Existing EDR models require a three-wire 120VAC, 20A, 60Hz power source (grounded neutral). New equipment could be designed to meet customer specific power needs.

Training

Electroimpact will provide safety training to our EDR customers, either in our facility or theirs, with the purchase of any new EDR and as periodic refresher courses. This training is for the most part limited to basic safe operation and proper care of the EDR to ensure a long product lifetime. During training we will pass along tips and techniques for use, but ultimately it will be up to the customer to develop the necessary skills to effectively pull dents.

EDR in Service

  • American Airlines
  • Boeing Airplane Company
  • USAF, 135 Production Engineering Branch, 76th Aircraft Maintenance Group
  • "I never cease to amaze at how few people in the industry, including operators, manufacturers and insurers of aircraft, are aware of this technology. I have personally handled roughly a dozen claims for hail damage, bird strikes and other sources of fuselage, wing and control surface damage on corporate aircraft...and I would estimate that I have saved over $2,000,000 in repair costs"
    - Kyle D. Moore, USAIG
  • "...A team from Boeing's Recovery and Modification Services came to our facility to perform dent removal on two Lear 60 model aircraft with their [Electroimpact] Electromagnetic Dent Removal equipment. We have been pleased with the results of this process. The two aircraft were damaged in a recent hail storm and had extensive amount of dents on the fuselage, delta fins and wing leading edges. Some of the dents were completely removed while others were removed to acceptable Structural Repair Manual limits. The process was time and labor saving."
    - Christopher L. Rabe, Manager Quality Assurance, Bombardier Aerospace Services
EDR FAQ

Can your machine remove the dents from my airplane?

Maybe, but possibly not. Whether or not the EDR will be able to remove any given dent is very difficult to know in advance of trying. Some dents are more amenable to the EDR process than others. Dents that are near a rib but not directly over the rib tend to be most obliging. Skin dents that are farther distant from any internal support structure tend to be less cooperative. Creases are particularly difficult. Dents that have caused the metal to stretch cannot be fully removed by the EDR process (though it may be possible to reduce their depth somewhat).

Can you come pull the dents out of my airplane, or do I need to bring my airplane to you?

Neither. We are not in the business of pulling dents out of airplanes ourselves. We build the machines that do the dent removal.

Can the EDR pull a dent out of an automobile?

We are not aware of a case where this was an effective solution.

How much does one of your EDR machines cost?

At the present time, the cost of an Electroimpact EDR machine is $500,000 USD. The EDR coils are sold separately. They are $2,500 each.

Can you lease me an EDR?

No.

My company is ready to purchase an Electroimpact EDR. How soon can you deliver it?

Delivery time for an EDR is 14 months after a contract is placed.

What are the sale terms for an EDR?

We require $150,000 with the order and $350,000 upon shipment.

Can you sell an EDR to a foreign customer?

Yes.