Best Way to Cut Carbon Fiber

[wdfifteen]

I need to cut some moderately complex shapes out of thin (about 1/16 inch or so) carbon fiber panels. The pieces will be about a foot long and roughly the shape of the state of Florida. What is the best way to make the cuts?

[legion]

Is it cured or uncured?

[wdfifteen]

^^

It's this. 1/16x6x24
Carbon Fiber Plates

[legion]

I've generally seen people using cutting wheels or bandsaws, though I don't know if they use a special blade.

[Nordwest]

Jig saw with fine grit blade. Lowes or Home Depot will have what you need.

[Seahawk]

There are scissors specifically designed for cutting pre-preg and other carbon fiber products.

Scissors, Cutters and Tools for Composites in Stock | Fibre Glast

Depending on the ply, orientation of the plys, thickness, etc., cutting isn't that hard.

There is probably a firm with a CNC cutter in your area that would do the work for you.

We do both all the time for jobs like yours, especially complex shapes.

[BlueSkyJaunte]

WEAR A MASK! Carbon fiber dust is bad stuff. VERY bad.

That said, I vote water jet.

[whiskyb]

I made templates years back that enabled me to use my router with a fine cutting bit. Wear a mask and hook up a extraction vac if you can

[pksystems]

Ultrathin cutoff disc on an angle grinder for a rough cut and then sand it down.

[Bill Douglas]

Originally Posted by BlueSkyJaunte

WEAR A MASK! Carbon fiber dust is bad stuff. VERY bad.

My first thought too.

[Bob Kontak]

Originally Posted by pksystems

Ultrathin cutoff disc on an angle grinder for a rough cut and then sand it down.

For $15 you can buy a pack of five discs and a special quick change arbor for a dremel.

Alternatively, you can get a 1/8" dia router bit - it liiks like a drill bit - and use a small Bosch router. This will cut way prettier than the dremel.

[nota]

on the linked site

''Plates can be cut to size or machined to print via CNC milling or waterjet cutting''

so let them do it

[wdfifteen]

^^
I need to experiment with sizes. I'll need to do the cutting or have it done locally.

[hardflex]

If it's cured, a carborendum bladed will work for not too many cuts, and is cheap. For a lot of cuts, a diamond blade is what I used to use with a water bath, similar to tile saws.

[island911]

Originally Posted by wdfifteen

^^

It's this. 1/16x6x24
Carbon Fiber Plates

Just use some of those carbon fiber-look stickers. You can cut that with scissors.

I mean, clearly you aren't using that bling stuff for expected engineering properties, right?

[cstreit]

A bunch of them? Water jet.

[look 171]

For small straight cuts, I use a 60 tooth carbide tipped blade on a chop saw (wood cutting). Band saw or jig saw with a fine blade, like someone wrote earlier. I don't do too much with carbon, but is I am in the shop, the band saw is the go to tool.

[Seahawk]

I have to ask...what are you making?

Complex carbon fiber shapes are hard to do right, and we build a lot of them: Ply schedules, ply orientation, matting, structural loads, etc.

Are you using a mold? Do you know bake times, etc.?

Again, just curious. My partner is an nationally recognized expert in advanced carbon fiber materials and design.

[dsfnctn]

this on a multitool is what i use

https://feintools-online.com/63502106210-fein-starlock-hss-segment-saw-blade-3-3-8-1-pack.html

[wdfifteen]

Originally Posted by Seahawk

I have to ask...what are you making?

It's nothing fancy. It's called a Morton Extension. Basically, I'm making custom insoles for my shoes. If you buy them from an expert they are $50 per foot, and if they don't fit right - too bad. I can buy the material to make 4 for $55, and I "hope" I can cut them so they actually do the job.



The carbon fiber part costs $50 or more.



The whole shebang can cost hundreds. I've spent almost a grand since I quit running to get something that works. I'm tired of leaving it to experts.