THIS PAPER EXAMINES THE DESIGN AND DEVELOPMENT OF A BRUSH-BASED ACTIVE ROBOTIC DEBURRING (BARD) SYSTEM FOR LARGE ALUMINUM CASTINGS. TOOL EVALUATION RESULTS WERE USED TO DEVELOP THE BARD SYSTEM BASED ON A KNOT TYPE END BRUSH, SELECTED FOR ITS COMPLIANCE, OPERATIONAL FLEXIBILITY AND RELATIVELY HIGH MATERIAL REMOVAL RATE. THE BARD SYSTEM IS THE RESULT OF A FEASIBILITY STUDY PERFORMED TO EVALUATE ROBOTIC DEBURRING FOR LARGE ALUMINUM TRANSMISSION HOUSINGS.