Customized Carbon Fiber Machining Service
We provide precision CNC machining services for CFRP composite materials, achieving tolerance accuracies of up to ±0.01 mm. We are AS9100D certified and capable of manufacturing production-grade components for humanoid robots based on rapid prototyping.
What is the CNC Machining of Carbon Fiber?
Carbon fiber machining is the highly controlled process of cutting, shaping, and finishing Carbon Fiber Reinforced Polymer (CFRP) composites with the use of advanced computer software. Such materials are made of carbon fibers (5 - 10 micrometers in diameter) in epoxy resin and are advanced composites.
Strength-to-weight ratio
5 times stronger than steel, 2/3's the weight
Tensile Strength
3 - 7 GPa (aluminum: 0.3 GPa)
Thermal Expansion
Near-zero CTE offers dimensional stability
Corrosion Resistance
Rust and the majority of chemicals have no effect to it
Carbon Fiber Application Areas
Customized carbon fiber solutions meeting the rigorous demands of various industries
Automotive & Motorsport
High-performance CFRP parts for EVs, supercars, and racing applications.
Common Applications
- Body Panels & Hoods
- Suspension A-arms
- Drive Shafts
- Battery Enclosures
- Interior Trim
Industry Focus
Precision machining for automotive parts, delivering extreme strength-to-weight ratios.
Drones & UAV
Lightweight frames and components for commercial and racing drones.
Common Applications
- Quadcopter Frames
- Motor Arms & Booms
- Gimbal Brackets
- Agriculture Sprayers
Industry Focus
Ultra-light yet rigid structures designed for superior flight performance.
Aerospace & Defense
Flight-critical components compliant with AS9100 and NADCAP.
Common Applications
- Fuselage Panels
- Wing Structures
- Control Surfaces
- Satellite Structures
Industry Focus
Aerospace-grade precision machining for mission-critical parts.
Medical Devices
Radiolucent, bio-compatible components for imaging and surgery.
Common Applications
- CT Scan Tabletops
- MRI Coil Housings
- Surgical Tools
- Prosthetic Components
Industry Focus
Enhancing medical diagnostics through carbon fiber innovation.
Robotics & Automation
Low-inertia components for faster cycle times and higher accuracy.
Common Applications
- Robot Arm Links
- End Effectors
- Gripper Fingers
- Wafer Handling
Industry Focus
High-speed, high-precision parts for industrial automation.
Sports Equipment
Winning-grade carbon fiber components for professional athletes.
Common Applications
- Bike Frames & Forks
- Golf Club Heads
- Tennis Rackets
- Hockey Sticks
Industry Focus
Lightweighting for peak athletic performance.
We Solve CNC Carbon Fiber Machining Challenges
Working on carbon fiber requires industry experience and specialization. Here is how we tackle the challenges we face.
Delamination & Fiber Pullout
The separation of carbon fiber layers will jeopardize the strength of the structure.
Using diamond coated tools with optimized settings at a cutting speed of 80-150 m/min.
What We AchievedEfficient cooling applied to maintain structural integrity.
Rapid Tool Wear
Carbon fiber is 5-10x as abrasive as glass fiber.
Using PCD and diamond coated end mills at a controlled feed rate.
What We Achieved10-20x longer tool life than traditional carbide tools.
Heat Buildup
The low thermal conductivity of carbon fiber will degrade the resin.
Using internal coolant systems combined with a climb milling strategy.
What We AchievedPreventing thermal damage to the epoxy matrix effectively.
Conductive Dust Hazards
5-10μm particles may be respirable and also electrically conductive.
Using HEPA filtration for wet cutting and full machine enclosure.
What We AchievedA industry-leading dust capture rate of 99.66%.
Carbon Fiber CNC Machining
Frequently Asked Questions (FAQ)
- Delamination: Cutting forces causing the layers of carbon fiber to peel apart.
- Fraying and Fiber Pull-out: Fibers at the edges fail to cut cleanly, leaving rough burrs.
- Rapid Tool Wear: Carbon fiber is highly abrasive, causing standard tools to dull extremely quickly.
- Dust Hazard: The fine dust generated is harmful to the respiratory system and is conductive, which can cause electrical shorts in machinery.
- PCD (Polycrystalline Diamond) Tools: Offer the longest tool life, ideal for high-volume production, though more expensive.
- CVD (Chemical Vapor Deposition) Diamond-Coated Carbide Tools: Good cost-to-performance ratio, lasting significantly longer than uncoated tools.
- Specialized Carbon Fiber Routers: These often feature specific flute designs (e.g., diamond cut, compression routers) intended to push the material downwards or towards the center to prevent delamination and fraying.
Generally, dry machining is preferred.
While liquid coolant can lower temperatures and flush chips, mixing it with carbon fiber dust creates an abrasive sludge that is very difficult to clean and can clog machine systems. Furthermore, some resin matrices might absorb water, leading to dimensional changes or degradation of properties.
A better approach for heat and chip removal is using a powerful industrial vacuum system (dust extractor) positioned directly at the cutting zone. This keeps the workpiece clean, removes some heat, and most importantly, protects the operator and the machine.
- Use Compression Routers: Their up-cut and down-cut flute design compresses the material towards the middle, supporting both the top and bottom layers.
- Optimize Cutting Parameters: Use a higher spindle speed (RPM) and a lower feed rate to reduce the chip load per tooth and minimize cutting forces.
- Use a Backing Board (Sacrificial Board): Place a rigid material (like aluminum or hard plastic) underneath the part and cut through into it during drilling or routing. This provides support for the bottom layer of fibers.
- Climb Milling: When profiling edges, climb milling generally yields a better surface finish than conventional milling.