I'm sure you've had many prints come across your desk for quoting that required some form of a internal profile or drive feature. Perhaps you've passed on these opportunities simply because you didnt have the required tooling to generate such forms in a production setting?

Fear not, Rotary Broaching is a potential solution.

[ame="http://www.youtube.com/watch?v=BhvNU2E_x_Y"]How Rotary Broaching Works[/ame]

The clear acrylic used for the demo shows how the tool shapes a round predrilled pilot hole into hexagonal hole.

-Scott@Genswiss