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Old 07-18-2002, 04:56 PM   #1
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cutting carbon fiber

how is this done properly?
i was using a 1/4" end mill in my router with great success, but i was tracing an existing chassis for most of the design. i was using a .252 id thin wall aluminum tube to ride over the bit exposing the tip to cut the blank while the alum would ride the old chassis which was screwed in two places to the blank. well after two inches the heat and force gobbled up the aluminum and into the template chassis i went.
so far, i not only screwed up my blank, but now the original is marred.
what can i use to trace to old? same idea, but with stainless?
for those of you who've done it, how do you do it?
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Old 07-18-2002, 05:15 PM   #2
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Let a professional do it... I hope you have a good resparator on... Carbon dust can be deadly if you breath it or get on you skin.
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Old 07-18-2002, 05:28 PM   #3
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http://www.rctech.net/forum/showthre...ight=carbon%2A
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Old 07-18-2002, 05:49 PM   #4
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Seaball,

I was going to do some carbon fiber work myself, my plan was to use a side cutting router bit, the kind that has a ball bearing on the end the same diameter as the cutting portion. Then you stack the carbon fiber plate with your template, and the ball nearing guides on the template while the cutter cuts the carbon fiber.

Like others have mentioned, use a really good respirator if you're going to work with this stuff.

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Old 07-18-2002, 06:30 PM   #5
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hey trips,
that's basically what i did, but i made my own flush cutting bit. i have that bit for my router, but as you may have said, you have to space the chassis about 1/4 " away from the blank to clear the gap between the cutter and the bearing.
that's not a bad idea. i bet my flush cutting bit is way to dull though. i'll try agian. thanks.
what? respirator? ummm yeah, i better get one.
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Old 07-18-2002, 06:33 PM   #6
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oh yeah, thanks jokur.
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Old 07-18-2002, 06:39 PM   #7
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...also wear gloves and long sleeves. Graphite is shaped like little arrows:

>>>>>>>

Once the splinters go in, its VERY HARD for them to come back out. Even the dust can get rubbed into the skin and cause bad itching for days.
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Old 07-18-2002, 07:11 PM   #8
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Hi guys,

check out www.fiber-lyte.co.uk. They do customised parts.

save your health, let the pro with the right equipment do it.
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Old 07-18-2002, 07:36 PM   #9
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The Fibre Lyte link does not work.
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Old 07-19-2002, 01:45 PM   #10
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the correct address is http://www.fibre-lyte.co.uk ongbenghui got the R and the E the wrong way round
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Old 07-22-2002, 07:29 AM   #11
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My planned method of shaping CF sheets is to draw the outline on the CF with an offset of about 1mm - 2mm. Instead of using a router (I don't have one ) I would use a small drill bit and start drilling thousands of holes along the line until I finish the whole shape...

Then somehow, I would break the shaped chasis out from the sheet then use a high-speed dremel to smooth out the edges. I've never had the need to do this yet. I wish I won't have to, and I hope I won't get cancer in the process
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Old 07-22-2002, 07:31 AM   #12
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Maybe If I start very early in the morning I would finish cutting out the chassis by evening. Then spen another day cutting out the battery slots etc...


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Old 07-25-2002, 09:04 PM   #13
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hey when i drill through i get a poor backside. how are those holes cleaned out? i'm gonna try a countersink. hopefully that'll work. any better suggestions?
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Old 07-25-2002, 09:18 PM   #14
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try using higher drill speed and don't put too much pressure on the drill bit...

Let the bit eat through the material.

Do it slow...


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Old 07-26-2002, 02:19 AM   #15
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A jigsaw can be used to cut the carbon fibre. Although you will need to make sure your using a blade that won't blow out the bottom layer. A trimmer (small router) with a flush cutter in it would be my preferred choice. Don't use expensive trimmer bits like CTM because the CF will kill them very quickly best bet is to buy 2 or 3 cheap chinese bits from the local hardware.

Also, it's the fibreglass that causes cancer and the itching,the carbon is not so dangerous. The small particles of glass get in you skin and lungs which then scratch the tissue in the lungs causing cancer. This said, a dust mask would be sufficent for the small amounts that most people do at home. It's only when you use the stuff day in and day out as I do that a resporator would be nessesary.

How do you guys layup your carbon. I'v looked at a few chassis and they all seem to be 4 layers of plain wieve, approx 6oz but I was just wondering what others are using. Any one use a core material.

Sorry if I come off as a bit of a know all but I have much knowledge of all different types of composite materials. Iwork with the stuff for a living. please feel free to ask any questons and I will do my best to answer.
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