A new hybrid oscillatory orbital process, using superabrasive diamond tools, was developed for drilling FRP composites. Effects of grain size and tool geometry on forces, temperatures, and surface integrity were experimentally investigated. With proper selection of cutting conditions and process variables, the limitations of conventional orbital drilling using carbide tools can be eliminated by significantly reducing the forces and surface roughness, while increasing tool life by an order of magnitude. This is comparable to PCD tools, at a fraction of the cost. A force model based on process kinematics and chip formation mechanism was developed and validated.