Rifling significantly influences firearm accuracy by creating spiral grooves in the barrel. This gives the projectile a rotational trajectory, enhancing its stability and precision, which are increasingly critical with greater shooting distances. 

Explores the challenges of firearm manufacturing and highlights the crucial importance of deburring and rifling to achieve the best possible finish.

Why do firearms need the greatest technologies like electrochemical rifling?

The need for advanced technologies in rifling becomes imperative for several reasons:

Precision for shooters

Modern firearms demand unparalleled precision to meet the expectations of shooters, whether for recreational purposes or in critical applications like law enforcement and military operations. 

The slightest deviation in rifling can significantly impact bullet trajectory and accuracy. Advanced technologies offer the precision to create consistent and uniform rifling patterns, ensuring optimal performance.

Barrels customization

Modern firearms are increasingly tailored to individual preferences, with shooters seeking custom features and configurations. 

Advanced rifling technologies provide greater flexibility for customization, allowing manufacturers to produce barrels with specific twist rates, groove profiles, and rifling configurations to meet diverse customer demands.


Consistency for bullet flight

Consistency is key in firearm manufacturing to ensure that each weapon performs reliably and predictably. 

Traditional rifling methods may produce variations in groove depth, spacing, or alignment, leading to inconsistencies in bullet flight paths. 

Advanced technologies, such as electrochemical rifling, offer greater control over the rifling process, resulting in uniform grooves and consistent performance across multiple firearms.


Efficiency and competitivity of firearms manufacturers

Advanced rifling technologies offer significant advantages in a competitive market where speed-to-market and production efficiency are paramount. 

Processes like electrochemical rifling can produce rifled barrels more quickly and with less manual intervention than traditional methods. This improves manufacturing efficiency and reduces costs associated with labor and production downtime.

Advanced rifling processes also position companies as industry leaders, attracting discerning customers and driving market share growth.

Production quality control for firearms

With stringent quality standards and regulations governing firearm manufacturing, technologies that enable precise quality control are indispensable. 

Advanced rifling technologies ensure that each barrel meets exacting specifications, minimizing defects and enhancing overall product quality.

In essence, the pursuit of the latest and greatest technologies in rifling is driven by the relentless quest for excellence in firearm design, performance, and manufacturing. 

As shooting sports evolve and the demands placed on firearms become more exacting, the role of advanced rifling technologies becomes increasingly indispensable in meeting these challenges head-on.

EC rifling to face traditional rifling methods drawbacks

A new technology, electrochemical rifling (EC), emerges as a promising alternative to traditional rifling methods, such as cut rifling, broach rifling, and button rifling, which have drawbacks such as producing burrs or applying stress to the barrel. 


What is EC Rifling?

EC Rifling, or Electrochemical Rifling, uses material dissolution and Faraday’s law of electrolysis to create precise grooves in the barrel without any physical contact, thereby eliminating stress on the barrel. 


EC rifling Extrude Hone history

In 1986, CATION Corp. obtained a patent for a method and apparatus for electrochemical (EC) rifling of gun barrels (United States Patent US4690737A). This patent was later transferred to Robert Bosch Corp. in 1990 and eventually reassigned to Surftran Manufacturing LLC.

Extrude Hone entered the scene by acquiring the Robert Bosch Surftran Division, which included product lines for electrochemical machining (ECM) and thermal deburring (TEM), in 2000. 

Before this, Extrude Hone established a presence in the ECM industry by distributing AEG Elotherm products in North America starting in 1974 and beginning to manufacture ECM machines in 1975.

The company expanded its ECM business with acquisitions such as VMB Vorrichtungs- und Maschinenbau Babenhausen GmbH and DIVA-TEC GmbH. By 2007, Extrude Hone consolidated all its ECM operations under Extrude Hone GmbH, solidifying its position as a key player in the ECM industry.

Extrude Hone’s electrochemical rifling (ECR) distinguishes itself by offering a level of precision and quality beyond the capabilities of traditional methods. With a legacy spanning more than two decades, EC rifling has consistently delivered superior results in rifling quality.

How does EC Rifling work? 

This method relies on electrolytic machining (ECM), which uses an external direct current power source to dissolve the metal anodically. The electrolyte, such as NaCl or NaNO3, facilitates charge transfer in the working gap to allow metal dissolution.

Extrude Hone has developed an electrochemical rifling machine called ECO+ that offers superior precision and quality compared to traditional methods. With consistent and high-quality results, this machine can perform polygonal rifling on an 86mm handgun barrel in 70 seconds. 

Furthermore, electrochemical rifling has advantages such as no stress applied to the barrel, the ability to process different materials with the same tools and configurations, flexibility in twist progression, and consistent quality for firearm manufacturing.

This method allows easy switching from a rifling process to a deburring process, increasing its efficiency and versatility even more. More about EC rifling in this page.

Electrochemical rifling configurations

Static EC rifling for handguns and shorter barrels

Static EC rifling is tailored for handguns and shorter barrels. A static cathode is positioned on the tooling base plate. The barrel is brought on top of the cathode and immobilized to ensure good anodic contact, initiating the electrochemical cycle.

Different generator power sizes allow for various applications, and simultaneous processing of multiple parts or barrels is possible.


Dynamic EC rifling is designed for longer barrels

Dynamic EC rifling is catering to the diverse needs of the firearms industry. In this configuration, the cathode travels down the barrel at a given feed rate and twists from the top of the machine. Although potential groove deformation may occur due to current variation, the tooling includes extra barrel extensions to absorb this, ensuring a perfect barrel. 

Extrude Hone’s dynamic rifling machine can accommodate three 800mm barrels.

A noteworthy aspect of dynamic ECM is the use of plastic from the cathode to ensure cathode centering as it moves back and forth through the barrel. Specific materials and removal inserts facilitate easy cathode maintenance, reducing consumable costs per part.

250 Working days, 2 shifts @10h @ 85% Efficiency

Extrude Hone’s solutions for Electrochemical rifling

For firearms manufacturing, ensuring consistent quality is paramount. With a legacy spanning over two decades, Extrude Hone has consistently delivered superior results in rifling quality with EC rifling.


Electrochemical rifling machines

Tailoring machine selection to specific needs is crucial, particularly when considering electrochemical (EC) machines. These machines should offer versatile configurations for EC rifling, static, or dynamic processes, accommodating barrel lengths of up to 800mm. 

Machines can be equipped for robot loading/unloading for large-volume production, enhancing efficiency and throughput.

One of the key benefits of an electrochemical machine is its versatility. Depending on the manufacturer’s requirements, it can seamlessly switch from a rifling configuration to a deburring one. This flexibility allows for optimized production processes and efficient resource use.

Imagine a scenario where a gun breech requires precise deburring in specific areas. Extrude Hone systems enable users to switch from rifling tooling to gun breech deburring tooling effortlessly. 

Users can seamlessly transition between different manufacturing tasks by selecting the alternative program from the preset library, maximizing productivity and asset utilization.

Stop dreaming about it, this is now a reality: ECO+ offers the best solution for Electrochemical rifling.

Contract shops for electrochemical rifling services

Additionally, contract shop services are available in the U.S. and Europe for manufacturers who cannot justify investing in equipment. Leveraging Extrude Hone’s contract capabilities provides customers access to experienced professionals and ensures quick turnaround times without compromising quality.

Extrude Hone’s overarching goal is to enhance efficiency and produce flawless parts. 

By offering versatile machine configurations, seamless transitions between manufacturing processes, and contract shop services, Extrude Hone aims to support manufacturers in achieving their quality and production goals.