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gorillapaws's avatar

Will I get good results using a flush trim router bit on 3mm carbon fiber plate?

Asked by gorillapaws (30865points) May 18th, 2021

I’m trying to cut out some geometry from a 3mm carbon fiber plate. I’ve 3d printed a plastic profile of the part I need. My plan is to attach the plastic part (with clamps, double-sided tape, through holes and bolts?—suggestions welcomed) and then trace the shape with a flush trim bit on my router. I’m just wondering if this will lead to a nice result of if it’s going to mangle the edge of the finished work. Do I need to buy a special kind of flush trim router bit for this operation or would the ordinary one in my basic router bit kit work?

I should add I do plan to wear long sleeves and my N95 mask, and perform the cuts outside. Any additional advice?

Thanks in advance for any suggestions or advice!

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3 Answers

RocketGuy's avatar

Carbon fiber composite edges will not mangle like Kevlar. It cuts more like fiberglass but downward forces could cause delamination. If you can trap the edges between two layers of support material, you will prevent that. Something with clamping action would be best e.g. clamps or thru bolts. At work we do endmill and drilling using a backing board material. Standard carbide bits (only because they are cheap). Carbon composite eats bits, just like fiberglass. Diamond bits would last longer but cost a lot more.
Long sleeves and N95 will be fine. Carbon fibers are not as obnoxious as glass fibers in terms of poking into your skin. Suction would be really good. We use only house suction at work, with the vacuum system outside the building. That way particles finer than the bag mesh won’t get breathed in by the machinists.

gorillapaws's avatar

@RocketGuy Thanks for taking the time to post your great answer! The sacrificial support material is a great idea. I’ll be sure to run the shop vac too.

RocketGuy's avatar

Carbon composites is my thing. I used to work in the composites dept, with an office above the composites machine shop.

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