How to Remove the Broken Taps?

Broken taps are one of the most common—and frustrating—problems in machining, mold making, and metalworking. When a tap breaks inside a workpiece, it not only interrupts production but can also damage the part, delay delivery, and increase manufacturing cost. Fortunately, there are several effective methods to remove broken taps without ruining your component. In this article, we will explain practical and widely-used techniques, along with tips to prevent tap breakage in the future.

Why Do Taps Break?

Before we discuss removal methods, it helps to understand why taps break. Common reasons include:

Using the wrong tap size or material
Poor lubrication during tapping
Misalignment between tap and hole
Excessive torque during hand tapping
Hard or tough materials such as stainless steel
Chips failing to evacuate from the hole

Method 1: Use a Tap Extractor

Tap extractors are specially designed tools with flexible fingers that fit into the flutes of the broken tap.

How it works:

Insert the extractor fingers into the tap flutes.
Tighten the collar to secure the extractor.
Turn the extractor counterclockwise to remove the broken tap.

Advantages:

No damage to the existing thread.
Simple and inexpensive.

Best for:

Lightly broken taps where the top is still accessible.

Method 2: EDM Removal

EDM is the most professional and reliable method—especially used in mold factories and precision machining workshops.

How it works:

A small electrode burns away the tap material without touching the workpiece.
The tap turns into fine powder and is flushed away.

Advantages:

No mechanical stress on the part
Can remove taps deep inside blind holes
Works for hardened steel taps and hard materials

Best for:

Taps broken inside high-value parts
Hard-to-reach or deep holes
Precision mold components

If your factory has EDM machines, this will be the safest method with almost no scrap risk.

Method 3: Using a Punch and Hammer

If the tap is small and brittle (such as HSS taps), you may break it into pieces.

How it works:

Use a small punch to tap the broken section.
Break the tap into fragments.
Remove fragments with tweezers or compressed air.

Advantages:

Fast and requires no special equipment.

Disadvantages:

Risk of damaging the threads

Not suitable for delicate or expensive parts

Method 4: Drilling Out the Tap

If the tap is not too hard, it can be drilled out using carbide drills.

Steps:

Use a center punch to mark the center.
Use a small carbide drill to remove material.
Gradually increase the size until the tap collapses.

Best for:

Larger broken taps
Non-hardened materials

Note:

Requires good alignment; otherwise, it may damage the thread.

Method 5: Chemical Removal

Some chemicals can dissolve high-speed steel without affecting the base material (e.g., alum for aluminum parts).

How it works:

Soak the part in a warm alum solution.
The broken tap gradually dissolves.

Best for:

Aluminum workpieces
Taps stuck in soft metals

How to Prevent Tap Breakage?

Prevention is always better than removal. Follow these tips:

Use high-quality taps
Ensure proper alignment
Apply enough cutting fluid
Reduce tapping speed for hard materials
Back off regularly to clear chips
Use thread milling for difficult materials

Removing broken taps is a challenge, but with the correct method—tap extractors, EDM, drilling, or chemical dissolution—you can recover the part and avoid scrap. For precision mold parts and high-value components, EDM is often the safest and most accurate solution. By using proper tapping techniques and lubrication, you can significantly reduce tap breakage and maintain stable machining quality.