The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company ? Egypt to perform the experimental work, and the tools were offered by Flowdrill Company ? Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.