The SD-109 1" Ball Shaped Aluma Cut Carbide Burr 1/4" Shank (116-66204-AC) is a precision-ground, USA manufactured solid tungsten carbide burr in the Aluma-Cut Carbide Burr. With a 1" head diameter, 1" length of cut, and a 1/4" X 2" shank, it delivers controlled stock removal and clean finishes. Its Aluma-Cut open flute geometry prevents loading and clogging on aluminium. Available in Aluma-Cut.
Available in Aluma-Cut
Open flute geometry prevents loading on aluminium and non-ferrous metals
Solid tungsten carbide, not coated steel
Head diameter 1", length of cut 1", shank 1/4" X 2"
USA manufactured
Head Diam1"
Cut Length1"
Shank1/4
OAL2
Specifications
SKU / Part Number116-66204-AC
Shape / TypeAluma-Cut
Cut TypeAluma-Cut
Head Diameter1"
Shank Diameter1/4
Length of Cut1"
Overall Length2
MaterialSolid Tungsten Carbide
Material CompatibilityAluminium and non-ferrous metals
Brand / ManufacturerCarbide Burrs Direct
Made InUSA
Key Features
◆Aluma-Cut open flute geometry
Specially designed open flute pattern prevents aluminium and soft non-ferrous chips from loading and clogging the cutting edges.
◆Tight-tolerance grinding
Head diameter held to +/-0.001" for repeatable results at the 1" head size.
◆Optimised for aluminium and non-ferrous
Aluma-Cut is the correct choice for aluminium, copper, brass, and soft alloys where standard cut burrs load up.
◆USA manufactured quality
Every Aluma-Cut burr is ground in the USA to ANSI tolerances with documented traceability.
Use this guide to pick the right 116-66204-AC configuration for your application before ordering.
Choose Aluma-Cut if...
Working on aluminium or soft non-ferrous metals
Standard burrs are loading up or clogging on your material
You need a clean smooth finish on aluminium
Working on copper, soft brass, or plastic composites
Aluma-Cut is specifically engineered for aluminium. Using it on steel will reduce tool life.
Choose Standard or Double Cut if...
Working on cast iron, steel, or hard alloys
Your application requires aggressive stock removal on ferrous metals
Surface finish on steel or cast iron is the priority
You need compatibility across mixed materials
For steel, cast iron, and hard alloys, Single Cut or Double Cut delivers better performance and longer life.
Compatibility note: The 116-66204-AC uses a 1/4 shank. Verify your collet accepts this diameter before ordering. Call 1-844-313-7153 with questions.
Frequently Asked Questions
What materials is the 116-66204-AC Aluma-Cut designed for?
The SD-109 1" Ball Shaped Aluma Cut Carbide Burr 1/4" Shank Aluma-Cut is specifically engineered for aluminium, soft copper, brass, and non-ferrous alloys. Its open flute geometry prevents chip loading and clogging. For cast iron, steel, and hard alloys, use a standard Single or Double Cut burr.
Can the 116-66204-AC Aluma-Cut be used on steel or cast iron?
Aluma-Cut burrs are not recommended for ferrous metals like steel or cast iron. The open flute geometry is optimised for soft non-ferrous materials and will wear prematurely on hard ferrous metals.
What RPM should I run the 116-66204-AC at?
For a 1" head diameter, recommended surface speed is 35,000 to 50,000 RPM. On aluminium, higher RPM generally produces a cleaner finish. Call 1-844-313-7153 for application-specific guidance.
Customer Reviews
4.8
★★★★★
Based on 5 verified purchases
BS
Brian S.
Santa Ana, CA
★★★★★
October 2023
Perfect for die casting cleanup
Been using the SD-109 1" Ball Shaped Aluma Cut Carbide Burr 1/4" Shank for several months. Consistent results every run. The Aluma-Cut option is exactly right for this work. Fast shipping from Santa Ana, CA, had it on my bench in two days.
Verified purchase · Aluma-Cut
LK
Laura K.
Chula Vista, CA
★★★★★
August 2023
Best tool at this size I have found
Needed a reliable tool for deburring steel brackets and the SD-109 1" Ball Shaped Aluma Cut Carbide Burr 1/4" Shank delivered. Runs true, consistent finish every time. Called 1-844-313-7153 before ordering and got great advice.
Verified purchase · Aluma-Cut
PM
Priya M.
Irvine, CA
★★★★★
February 2024
Great quality, fast ship
Ordered for weld seam cleanup work. Quality is noticeably better than import alternatives. The Aluma-Cut gives excellent results. Will reorder without hesitation.
Verified purchase · Aluma-Cut
JL
Jason L.
Oakland, CA
★★★★☆
December 2023
Called before ordering, excellent advice
Was not sure which configuration for automotive bodywork. Called 1-844-313-7153 and got real help. Went with Aluma-Cut, exactly the right call.
Verified purchase · Aluma-Cut
AJ
Andre J.
Long Beach, CA
★★★★★
May 2024
Consistent quality every order
Shop supervisor at a fabrication facility. We use the SD-109 1" Ball Shaped Aluma Cut Carbide Burr 1/4" Shank for jewelry repair detail work regularly. Outlasts big-box imports by a wide margin. Reordered multiple times. USA manufactured and it shows.
Verified purchase · Aluma-Cut
Why Choose Carbide Burrs Direct
01USA manufactured
Every product is manufactured in the USA to ANSI tolerances, not an import rebranded with an American sticker. Documented traceability and consistent quality batch to batch.
02Direct pricing, no distributor markup
We sell direct from our warehouse at 1846 So Grand Ave, Santa Ana, California 92705. No rep, no middleman, no inflated list price. The price machinists and fabricators actually pay.
03Same-day shipping on in-stock orders
Orders placed before 2 PM PST on business days ship same day from Santa Ana, CA. Call us at 1-844-313-7153 to confirm stock before you need it on the floor.
04Expert phone support
Not sure which cut type or configuration is right for your application? Call 1-844-313-7153 and our team will get you the right tool the first time.
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