How to Cut Carbon Fiber? - Everything You Should Know

Cutting carbon fiber can be a precise and delicate task. When it comes to cutting this durable material, using the right tools is essential. Opt Lasers' Blue Laser Heads offer a solution that provides both accuracy and efficiency for carbon fiber cutting. In this guide, we will show you how to cut carbon fiber effectively using various methods available, and what each method is good for. With Opt Lasers, mastering how to cut carbon fiber has never been easier.

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Before You Cut CF: Methods and Tools

Cutting carbon fiber can be approached in several ways, each with its own set of tools and techniques. On the more manual side, tools like hacksaws, Dremel tools, drills, coping saws, angle grinders, and jigsaws are commonly used. These tools can be effective for smaller projects or when precision is not the primary concern. However, they require a steady hand and a lot of patience to achieve clean cuts, and often result in more waste and less precise edges.

For more automated and precise methods, CNC cutting tools such as mills and CNC router end bits are popular choices. These tools offer greater control and accuracy compared to manual methods. They are suitable for larger projects or when intricate designs are needed. While CNC methods improve precision and reduce manual labor, they still fall short in terms of efficiency and the quality of the final cut when compared to laser cutting technology.

Among the various cutting technologies available, using blue laser heads stands out as the most efficient and effective method for cutting carbon fiber. Blue laser heads, like those from Opt Lasers, provide unparalleled accuracy and clean cuts, significantly outperforming manual tools, CNC methods, and even other laser types like CO2 lasers. The focused energy of blue lasers allows for precise cuts with minimal material wastage and reduced edge fraying, making it the superior choice for all professionals working with carbon fibre. In addition, they benefit from high energy efficiency, and are very easy to integrate into existing setups.

Regardless of the cutting method chosen, safety precautions are paramount when working with carbon fiber. Manual cutting tools can produce fine dust and fibers, which can be harmful if inhaled or if they come into contact with skin. Using proper personal protective equipment (PPE) such as masks, gloves, and protective eyewear is essential. Similarly, CNC machines and laser cutters require appropriate ventilation systems to manage dust and fumes. Additionally, when using laser cutters, it's crucial to follow manufacturer safety guidelines to prevent burns, eye damage, and other injuries.

This section will delve into the details of each cutting method, highlighting their advantages and limitations, and providing comprehensive safety guidelines to ensure a safe and effective cutting process for your carbon fiber projects.

Laser Cutters for Carbon Fiber

Contary to common belief, a blue diode (or even CO2) laser cutter with the correct settings will not cause a visible burned cut line by burning the epoxy before it cuts the fibers. In particular, blue lasers are much less prone to this phenomenon than CO2 lasers. Notwithstanding, each of them can be tuned to cut your carbon fiber with exceptional top-notch results. In fact, laser cutters are revolutionizing the way carbon fiber can be cut, offering precision, efficiency, and flexibility. Among the various types of lasers available, blue laser heads and CO2 lasers are the only suitable laser types as of July for use in CF cutting. However, each has its strengths and weaknesses, making it essential to understand their suitability for cutting carbon fiber.

How to Cut Carbon Fiber with Blue Laser Heads for CNC Machines

Blue laser heads are considered the best option for cutting carbon fiber due to their superior energy efficiency, precision and control. Typically operating at a wavelength of around 440-450 nm, blue lasers can achieve highly focused laser beams, which translate to much cleaner cuts with minimal heat-affected zones. Blue lasers can cut carbon fiber with precision as high as 0.05-0.2 mm, depending on the laser head in question.

This precision reduces the risk of damaging the carbon fiber's polymer matrix and ensures the structural integrity of the material is maintained. Additionally, blue laser heads are highly efficient, consuming less power while delivering high performance. Compared to CO2 lasers, blue lasers are 4-5 times more energy efficient.

The image on the left below showcases the cleanly cut edges of a carbon fiber fabric circle, cut using Opt Lasers' blue laser heads. On the right, you can see the unburned surface of various black carbon fiber and white fiberglass sheets, all precisely and cleanly cut with a 45W XT8 blue laser head:

In addition, blue lasers' ability to cut complex shapes and designs makes them ideal for advanced manufacturing and prototyping. Blue lasers are mounted on a CNC machine, and the automated process allows them to cut carbon fiber 24/7. It however worth noting that whilst blue lasers are ideal for cutting carbon fiber cloth and fabric, and they perform well on carbon fiber veneer, they should not be used for carbon fiber laminates.

CO2 Lasers

CO2 lasers, operating at a wavelength of 10.6 micrometers, are widely used in various industries for cutting non-metallic materials. While they are capable of cutting carbon fiber, they are not as precise as blue laser heads. CO2 lasers waste 95-96% of provided energy, and generate much more heat, which can affect the edges of the carbon fiber, leading to potential fraying and damage to the polymer matrix. This heat can also cause the resin to degrade and produce harmful fumes at a much greater scale. Despite these drawbacks, CO2 lasers are relatively versatile and can be used for a variety of materials, making them a more generalized tool in workshops and manufacturing environments.

Fiber Lasers

Fiber lasers are known for their high power and efficiency, operating at wavelengths around 1.064 micrometers. Unfortunately, their suitability for cutting carbon fiber is limited due to the significant amount of heat they generate per pulse. This excessive heat can severely damage the polymer matrix in carbon fiber, degrading the resin and causing it to burn. The resultant damage compromises the material's integrity and can release harmful fumes, posing health and safety risks. While fiber lasers excel in cutting metals and other hard materials, they are quite inferior for carbon fiber cutting due to these heat-related issues.

Comparative Analysis

When comparing blue laser heads, CO2 lasers, and fiber lasers for cutting carbon fiber, it is evident that blue laser heads offer the best performance. Their precision and efficiency make them superior in maintaining the integrity of the carbon fiber, while also ensuring cleaner cuts and less material waste. CO2 lasers, although versatile, fall short in terms of precision and heat management, making them less suitable for delicate carbon fiber work. Fiber lasers, despite their high energy efficiency, generate too much heat per pulse, leading to potential damage and safety concerns.

Cutting Carbon Fiber with CNC Mills and CNC Router End Bits

Cutting carbon fiber with CNC mills and CNC router end bits offers precision, efficiency, and versatility, making these methods highly suitable for both industrial applications and custom projects. Compared to manual tools, CNC methods provide superior accuracy, speed, and consistency, addressing many of the challenges associated with traditional cutting techniques.

Here are the recommended settings for cutting carbon fiber with a CNC mill or router:

• Carbon fiber veneer sheets: Use a spindle speed of 10,000 RPM and a cutting speed of 75 inches per minute.
• 1/16" carbon fiber sheets: Set the spindle speed to 10,000 RPM and cut at 60 inches per minute.
• 1/32" carbon fiber sheets: Maintain a spindle speed of 10,000 RPM and cut at 70 inches per minute.

These parameters ensure precise cuts and efficient processing while minimizing damage to the CF material.

CNC Mills

CNC mills are widely used for cutting carbon fiber due to their high precision and control. These machines operate by using rotary cutters to remove material, allowing for detailed and accurate cuts. CNC mills can typically achieve precision within the range of 0.1 mm to 0.01 mm, making them particularly effective for creating complex geometries and precise patterns in carbon fiber sheets and components. They are ideal for producing parts that require tight tolerances and high dimensional accuracy, such as aerospace components, automotive parts, and custom-fitted equipment.

The use of CNC mills in cutting carbon fiber also offers the advantage of repeatability. Once a design is programmed into the CNC machine, it can produce identical parts with consistent quality, making it perfect for mass production and large-scale projects. Additionally, CNC mills can handle various thicknesses and sizes of carbon fiber, providing flexibility in manufacturing different types of components.

CNC Router End Bits

CNC router end bits are another excellent tool for cutting carbon fiber. These bits are designed to work with CNC routers, which are known for their speed and versatility. CNC routers equipped with the right end bits can swiftly cut through carbon fiber, achieving precision typically within the range of 0.1 mm to 0.05 mm. The end bits come in various shapes and sizes, each designed for specific cutting tasks, such as straight cuts, detailed patterns, and beveled edges.

Advantages Over Manual Methods

Compared to manual tools like hacksaws and Dremel tools, CNC mills and CNC router end bits offer several significant advantages. CNC methods provide superior precision and control, allowing for more accurate and detailed cuts. They also operate at higher speeds, reducing the time required to complete projects. Additionally, CNC machines can handle more complex designs and produce consistent results, which is challenging to achieve with manual tools.

However, both CNC methods and manual tools share a common drawback: tool wear. Because they use contact methods to cut carbon fiber, the cutting edges of these tools gradually become blunt, reducing their effectiveness over time. This requires regular maintenance and frequent replacement of cutting tools, adding to the overall cost and effort.

Non-Contact Cutting with Lasers

In contrast, laser cutting offers a non-contact method that eliminates the issue of tool wear. Blue laser heads, such as those from Opt Lasers, use focused laser beams to cut through carbon fiber without physically touching the material. This non-contact approach means that users do not have to worry about the cutting tool becoming blunt. Additionally, laser cutting provides high precision and clean edges, further enhancing the quality of the final product.

The non-contact nature of laser cutting also allows for greater flexibility in cutting complex shapes and fine details. It reduces the risk of material damage and ensures consistent performance throughout the cutting process. As a result, laser cutting is increasingly becoming the preferred method for many carbon fiber cutting applications, offering significant advantages over both manual and CNC methods.

Manual Methods for Processing CF

Cutting carbon fiber manually involves a variety of tools and techniques that, while less automated than modern methods, offer a degree of control and accessibility that can be invaluable in certain situations. Whether you are a DIY enthusiast or a professional working on a specific project, understanding these manual methods can help you achieve precise and effective results.

Using a Hacksaw

One of the most common manual tools for cutting carbon fiber is the hacksaw. Equipped with a fine-toothed blade, a hacksaw can effectively cut through carbon fiber sheets and tubes. Typically, the thickness of a hacksaw blade used for cutting carbon fiber ranges from 0.5 mm to 1 mm. To achieve the best results, it's crucial to use a blade specifically designed for cutting composite materials. When using a hacksaw, ensure that the material is securely clamped to prevent movement, and cut slowly to minimize fraying and ensure a clean edge. Hacksaws are ideal for straightforward cuts and smaller projects where precision is not paramount.

Dremel Tools for More Precision

For somewhat more precise manual cuts, a Dremel tool can be highly effective. This versatile rotary tool can be equipped with various attachments, including cutting wheels and abrasive bits, making it suitable for detailed work on carbon fiber. Typically, the thickness of Dremel cutting wheels used for carbon fiber ranges from 0.8 mm to 1.0 mm. Despite the slightly thicker blades, the Dremel tool's high speed and rotary motion allow for more precise and controlled cuts compared to a hacksaw. It's essential to work slowly and steadily to avoid overheating the material, which can cause delamination.

Dremel tools are particularly useful for creating complex shapes and detailed patterns in carbon fiber:

1. Rotary Motion: The Dremel tool's rotary motion allows for smoother, more controlled cuts compared to the back-and-forth sawing motion of a hacksaw, which can lead to more jagged edges.
2. Speed Control: Dremel tools offer variable speed settings, enabling users to adjust the speed for optimal precision and control. This is particularly useful for delicate or intricate cuts.
3. Versatile Attachments: Dremel tools can be equipped with a variety of cutting wheels and bits designed specifically for precision work, whereas hacksaws are limited to their fixed blades.
4. Ease of Maneuverability: The compact size and design of the Dremel tool make it easier to handle and maneuver, especially in tight spaces or for detailed work.

Angle Grinder for Speed

Angle grinders are another powerful tool for cutting carbon fiber, especially when speed is of the essence. Fitted with a diamond or carbide cutting disc, an angle grinder can quickly slice through carbon fiber sheets and panels. However, due to the high speed and power of angle grinders, they can produce a lot of dust and generate significant heat, which can damage the carbon fiber if not managed properly. It's important to wear appropriate protective gear and ensure adequate ventilation when using an angle grinder.

Jigsaw for Versatile Manouvering

A jigsaw offers a versatile option for cutting carbon fiber, capable of handling both straight and curved cuts. Using a fine-toothed blade designed for cutting composites, a jigsaw can navigate various shapes and patterns. Typically, the thickness of the jigsaw blade used for carbon fiber cutting ranges from 0.5 mm to 1 mm. This fine-toothed blade helps ensure smooth, precise cuts with minimal fraying.

As with other manual methods, clamping the material securely and working slowly are key to preventing frayed edges and achieving a clean cut. It's essential to use blades specifically designed for composites to avoid excessive wear and tear on the blade and the material. Jigsaws are particularly beneficial for projects that require a variety of cuts and shapes, offering both flexibility and control to the user.

Coping Saw for Detailed Work

For very detailed work, a coping saw can be an excellent choice. This tool, with its thin, replaceable blade, allows for intricate and precise cuts. Typically, the thickness of a coping saw blade for cutting carbon fiber is around 0.3 mm to 0.5 mm. This thin blade helps ensure clean, precise cuts, making it especially useful for making interior cuts or navigating tight curves.

Due to its manual nature, a coping saw offers a high degree of control, allowing you to work meticulously on delicate sections of carbon fiber. However, it also requires patience and steady hands to avoid damaging the material. By working slowly and carefully, you can achieve detailed and accurate results, making the coping saw an invaluable tool for intricate carbon fiber cutting projects.

Drill for Starting Points

When making holes in carbon fiber, a drill can be an indispensable tool. Using a drill bit designed for composite materials, you can create starting points for other cutting tools or complete tasks like adding bolt holes or mounting points. To prevent splintering, it's best to place a piece of scrap wood under the carbon fiber while drilling and to use a slow, steady speed.

By understanding the various manual methods for cutting carbon fiber, you can choose the right tool for your specific project needs. Each method has its strengths and limitations, but with the right approach and technique, manual cutting can yield precise and satisfactory results.

Safety Precautions and Protective Gear

When cutting carbon fiber, safety is paramount. Different cutting methods require different safety precautions and protective gear to ensure the health and safety of the operator. Nevertheless, using blue lasers is in general the safest method for carbon fiber cutting as it doesn't generate the dust or splinters.

CNC Laser Processing Safety Precautions

Cutting CF with blue laser heads or CO2 lasers involves different safety measures due to the non-contact nature of the laser cutting process. Here are the specific precautions:

• Laser Safety Glasses: Wear laser safety glasses specific to the wavelength of the laser being used (different glasses for blue lasers and CO2 lasers) to protect your eyes from the laser beam. You should however never put your laser safety glasses directly in the path of the beam as it can damage them. You should also never stare at the beam directly.
• Air Exhaust System: Ensure an air exhaust or fume extraction system is in place to remove fumes and particulates generated during the cutting process. This is crucial as laser cutting can release harmful fumes from the carbon fiber resin. The best way to integrate an air exhaust system is inside an enclosure, as it minimizes the contact of fumes with external areas. In case some of the fumes exit the enclosure via the handling doors, you should wear respiratory protection.
• Well-Ventilated Environment: Besides the air exhaust system, the laser room or hall should also be appropriately ventilated
• Gloves for Handling: While the laser cut edges of CF are not sharp, you should wear gloves in case you are handling the parts before (or after processing) woth your hands.

Unlike manual or CNC cutting methods, laser cutting does not typically require special clothing or gloves since there is no physical contact with the material or particularly its cutting dust or splinters. However, always follow the manufacturer's safety guidelines to prevent accidental exposure to the laser beam.

Safety Precautions for CNC Milling and Routing

CNC mills and CNC routers equipped with end bits also generate dust and particles during the cutting process. While the precision and speed of CNC methods reduce the need for extensive manual labor, the following safety measures should be observed:

• Enclosure to protect the operator from generated dust and splinters.
• Safety goggles to protect the eyes from dust and particles.
• Respiratory masks to prevent inhalation of fine carbon fiber particles.
• Protective clothing to cover exposed skin and prevent irritation from carbon fiber dust and splinters.
• Gloves to protect hands during setup and material handling.
• Adequate ventilation or fume extraction systems to remove airborne particles from the workspace.

These precautions help ensure a safe working environment when using CNC tools to cut carbon fiber.

Safety Precautions for Manual Carbon Fiber Processing

Manual cutting tools like hacksaws, Dremel tools, angle grinders, and jigsaws can produce fine carbon fiber dust, splinters and particles that are harmful if inhaled or if they come into contact with the skin. It is also much easier for CF splinters, dust and particles to land on your skin and clothes while doing manual cutting, since you are much closer to the CF material being cut than when using CNC machines. Therefore, it is essential to wear much more appropriate personal protective equipment (PPE). This includes:

• Safety goggles to protect the eyes from dust and particles.
• Respiratory masks to prevent inhalation of fine carbon fiber particles.
• Protective clothing to cover exposed skin and prevent irritation from carbon fiber dust.
• Thick gloves to protect hands from splinters, sharp edges and particles.

Additionally, just like with any cutting method, ensure that you are working in a well-ventilated area to minimize the concentration of airborne particles.

Setting Up for Carbon Fiber Cutting

Configuring the laser head for optimal performance is crucial to achieve the best results when cutting carbon fiber. With Opt Lasers, you have the power to adjust various settings to suit your specific cutting needs. Make sure to position the laser head at the ideal distance from the carbon fiber surface to ensure precise and efficient cutting. This is typically the working distance (WD) of the given laser head, minus half the thickness of the material. Fine-tune the WD of the laser beam to achieve clean and sharp cuts without any charring or damage to the material.

Calibrating the Laser for Precise Cutting

To achieve the best performance, you need to use your laser at the correct working distance. Typically, you move your laser head so that the distance between the surface of the carbon fiber and the laser head is equal to the working distance in the laser head's technical specification. Then you normally need to adjust this distance by half the thickness of your material. Doing so ensures that the beam focuses exactly in the middle of the material. For thin carbon fiber sheets you may however chooso to fine tune this distance, moving the laser's focus closer to the fibers of the CF rather than the epoxy layer. In general accurate calibrations ensures getting precise and consistent cutting results every time.

To perform the working distance calibration, you need to engrave a set of lines on a piece of material, with each line corresponding to varying height above the material. For best results and precision, perform this test at low laser power on a piece of black anodized aluminium, or anodized aluminium business cards. Depending on the laser head and your anodized aluminium, a laser power of 5-10 Watts will be absolutely sufficient for this task. For black anodized aluminium, the closer you are to the perfect working distance, the more visible the engraving will be, as the laser beam engraves deeper into the anodization layer around the focus distance. As a result, you should see a pattern of decaying engravement thickness the further away you are from the perfect working distance (in both directions).

Notwithstanding, Opt Lasers' XT8 laser head allows you to enjoy more leeway with the way you position it. Effectively, for CF cut depths up to 3 mm, you can simply position it so that the distance between the laser head and carbon fiber surface is simply equal to its workinging distance. This is for instance useful for cutting carbon fiber sheets, which are comercially available in 0.25mm, 0.5 mm, 1 mm, 1.5 mm, 2 mm, and 3 mm thicknesses for a variety of sheets sizes. It will also be useful for cutting carbon fiber rods that are thin.

For CO2 lasers, it is quite different. CO2 lasers require frequent, difficult and time-consuming calibration. In addition, regular calibration is necessary for CO2 lasers to maintain cutting quality and efficiency over time. Having a well-calibrated CO2 laser is crucial for achieving precise cuts without compromising the integrity of the carbon fiber material.

Whatever laser you choose, make sure to follow the manufacturer's guidelines for calibrating your system to ensure optimal performance. By keeping your laser properly calibrated, you can increase productivity in your cutting projects.

Configuring the Parameters for Optimal Performance

Cutting carbon fiber requires a high level of precision, which can be achieved by configuring the paramters of your laser for optimal performance. Adjust the laser power, airflow rate, and cutting speed based on the thickness and type of carbon fiber you are working with. Experiment with different settings to find the perfect combination that delivers clean cuts with minimal heat-affected zones.

Helpful Tips and Techniques

There are several useful tips and techniques that help you improve the efficiency of your carbon fiber cutting station and mitigate the chances of any issues occurring.

Advanced Techniques for Thicker Carbon Fiber or Complex Shapes

1. Multi-Pass Cutting: Execute multiple passes with the laser head to gradually cut through the material. This approach ensures that the laser is focused exactly where it currently does the cutting work.
2. Variable Power Settings: If your carbon fiber is an object with variable thickness rather than flat one, you can alternatively compensate the extra thickness with additional laser power. Adjust the power settings of the laser to accommodate the varying thickness.

Tips for Achieving High-Quality Results

For the best results when cutting carbon fiber with tour laser, follow these tips to ensure high-quality cuts:

• Try to maintain a consistent movement speed of your CNC machine throughout the cutting process.
• Ensure that your CNC laser cutter machine doesn't vibrate too much.
• Optimize the cutting speed, working distance and airflow rate.
• Make sure your postprocessor compensates the laser power for when the machine accelerates and decelerates the laser

Maintaining a Consistent Laser Power Output

To achieve high-quality cuts when working with carbon fiber, it is important to maintain a consistent laser power output. Fluctuations in power can result in uneven cuts and affect the overall quality of your work. CO2 lasers are prone to this issue, while for high-quality blue diode lasers (like XT8 laser head) it is negligible as the power barely fluctuates.

If you use the CO2 laser, make sure to regularly check and calibrate your laser system to ensure a steady power output throughout the cutting process. This will help you achieve precise and uniform cuts every time.

Minimizing Heat Damage and Material Deformation

Excessive heat generated during the cutting process can lead to damage and deformation of the carbon fiber material. To minimize these risks, ensure that you are using the correct laser parameters and cutting techniques. Adjusting the power, speed, airflow rate, and working distance of the laser can help you control the amount of heat generated and reduce the risk of damage to the material.

Goto JCZ to know more.

For instance, using a lower power setting and/or a higher cutting speed can help reduce the heat-affected zone and minimize the chances of material deformation. Additionally, employing techniques such as air-assisted cutting or using a compressed air supply can help dissipate heat more effectively, further reducing the risk of damage to the material. By following these guidelines, you can achieve high-quality cuts while preserving the integrity of the carbon fiber material.

Common Challenges and Troubleshooting

Dealing with Laser Misalignment or Cleanliness

Misalignment of the laser can lead to issues with cutting accuracy and precision. If you notice that your cuts are not as clean or precise as they should be, the first thing to check is the alignment of the laser head.

As for the CO2 lasers, you should inspect all the mirrors and lenses for any signs of damage or misalignment. Even a slight deviation can have a significant impact on the quality of your cuts. Regular CO2 laser maintenance and alignment checks are vital to prevent misalignment issues and ensure consistent cutting performance.

For blue diode lasers, you should not see any issues with misalligment once you do the calibration on your first laser job. Instead, you should take a look at the front lens or the frontal protective window. Observe whether dust and debris has accumulated on it, and try to clean it gently.

If you continue to experience issues with misalignment, it may be necessary to contact the manufacturer for further assistance. They can provide guidance on troubleshooting steps or arrange for professional servicing to realign the laser and optimize its performance.

Resolving Issues with Inconsistent Quality

On occasion, you may encounter problems with inconsistent cut quality when working with carbon fiber. This can be frustrating, but there are steps you can take to address the issue. Start by adjusting the working distance of your laser with better precision using black anodized aluminium. A well-focused beam is vital for achieving clean and precise cuts.

Secondly, ensure that the cutting speed and power settings are appropriate for the material thickness and type of carbon fiber you are working with. Making adjustments to these settings can help improve the consistency of your cuts. Additionally, inspect the condition of the laser lens and clean it regularly to maintain optimal performance.

If you find that the issue persists, consider conducting test cuts on a small scrap piece of carbon fiber to fine-tune your settings and identify any potential factors affecting the cut quality. By systematically troubleshooting and making adjustments, you can overcome inconsistent cut quality and achieve the desired results.

Addressing Material Warping and Distortion

Inconsistent material warping and distortion can pose challenges when cutting carbon fiber with a laser. To address this issue, start by ensuring that the material is securely positioned and supported during the cutting process. Use clamps or fixtures to hold the carbon fiber in place and minimize movement that can lead to warping.

Adjust the cutting parameters to reduce the heat input and prevent excessive thermal stress on the material. Fine-tuning the speed and power settings can help minimize the risk of warping and distortion. Additionally, consider using a sacrificial layer or backing material to provide additional support and absorb excess heat during cutting.

FAQ

Question: What is carbon fiber?

Answer: Carbon fiber is a lightweight, strong material composed of carbon atoms bonded together in a crystalline structure. It is commonly used in applications where high strength and low weight are necessary, such as in aerospace, automotive, and sports equipment.

Question: What is the best tool to cut carbon fiber?

Answer: A blue laser head such as Opt Lasers' XT8 is the best tool to cut carbon fiber in a fast, precise and safe way.

Question: How to cut carbon fiber fabric without fraying?

Answer: To cut carbon fiber without fraying it is recommended to use a blue laser head, for instance Opt Lasers' XT8. Using XT8 at correct speed and power will elimiate all fraying.

Question: Is it OK to cut carbon fiber?

Answer: Yes it is - blue laser heads can cut carbon fiber with excellent results and smooth edges that won't cut your skin in turn.

Question: What is the best blade for cutting carbon fiber?

Answer: While worse than blue laser heads, diamond-coated abrasive cut-off blades are the best blades for cutting carbon fiber since they can avoid splintering or delamination.

Question: How do you cleanly cut carbon fiber?

Answer: To cleanly cut carbon fiber, you should use blue laser heads as they can provide the cleanest cut. For best-of-class results, you should also cover the cut edges with epoxy to seal them.

Question: Why use a blue laser head for carbon fiber?

Answer: A blue laser head is often preferred for cutting carbon fiber due to its high energy density and precise control. Blue lasers can produce clean, accurate cuts on carbon fiber material without causing damage or melting, resulting in smooth edges and minimal waste

Question: How to process carbon fiber with a blue laser head from Opt Lasers?

Answer: To cut carbon fiber with a blue laser head from Opt Lasers, you should first set the laser parameters such as power, speed, and focus according to the material thickness and desired cutting quality. Next, securely place the carbon fiber material on a flat surface and position the laser head accurately over the cutting area. Start the cutting process and ensure proper ventilation to remove any fumes generated during the cutting process.

Standardisation, achieved through tolerances is long standing, but essential for global trade

The concept of component interchangeability and dimensional tolerancing are an accepted part of modern manufacturing. The value of producing 'identical' parts that fit into any assembly of the same type has been around since , and probably earlier. Sir Joseph Whitworth developed the British Standard Whitworth (BSW) thread form, which forever improved distributed manufacturing. It enabled both competition and co-operation between differing manufacturing companies.

Perfection can hinder progress

It is easy to add tight tolerances and over constrain with Geometric Dimensioning and Tolerancing (GD&T) at the design and prototype stage. This will inevitably drive up manufacturing cost and limit sourcing options further along the development cycle. The most stringent tolerances may require secondary machining steps like grinding, polishing or Electro Discharge Machining (EDM) increasing both costs and more importantly lead-time.

Likewise, tolerances that are too loose can make assembling parts difficult or impossible.

To help navigate the types of tolerance and likely cost implications, this article covers tolerances available from Protolabs, along with commonly used tolerances. Finally, we will explore Geometric Dimensioning and Tolerancing (GD&T), defined under BS :, ISO and ASME.

Standardised tolerances for CNC machining

Many suppliers insist on a 2D drawing. Sometimes this is so they can charge extra for the tightest tolerances, and save by producing the rest of the component to a slacker General Tolerance (GT). Protolabs manufactures everything to a moderate standard tolerance of ±0.1 mm. keeping it simple saves time producing drawings and communicating. For the majority of components it is enough: 54% of functional components can be manufactured to a tolerance of ±0.1 mm or less.

Tolerancing guidelines for CNC machining

Over constraining a design can take two forms: either adding an unnecessarily tight tolerance, or constraining in each degree of freedom more than once ' a single pin will constrain in x and y, a second pin will prevent rotation. The same applies for slots and inserts ' over-constraining will add cost.

Surface finish

Typically, Protolabs offers a surface finish of 1.6 µm Ra (Roughness average) across the range of CNC materials. Ra 6.3 µm to Ra 0.8 µm are typical for general CNC machining. Optional bead blasting will result in a slightly rougher, but uniform, matt finish. See the surface finish guide for detailed images.

Designing in adjustment

Adding adjustment to a design can be a good way to get an accurate fit, and hedge your design bets, or test for the tolerance you may need:

• Shimming: (using a thin piece of material to adjust the height or gaps) using shim steel or shim washers.
• Adjustment screws: grub screws, or fine pitch screws can be used to alter position or push an assembly against a datum ' don't forget to consider how to lock the position (nylock nut, thread locking compound or another screw)
• Press-fitting: pressing 2 components to a known height or position
• Shrink fitting: by heating one component, thermal expansion can be used to lock two components accurately

All of these methods are great for jigs, test rigs and assembly equipment.

Modification during assembly

Bench fitting, fettling and polishing are all processes you definitely want to avoid if your product is destined for high volume manufacture. They are highly dependent on skill, and introduce variation. However, in the test and prototype phase using fine emery, lapping paste or polishing compound and a quick way to measure, can be a quick way to iterate your design to the necessary tolerance. Another tip is to produce multiple designs for assembly testing; CNC and 3DP can quickly produce a test array.

What are microns?

The micrometre (µm) is tiny at th of a millimetre; this is barely a 'smell': quite literally, a particle of cigarette smoke is 1 µm in diameter. When holding your mobile, the warmth of your hand will change its size by up to 68 µm. Which puts our general tolerance of ±100 µm into context ' avoid measuring in microns, unless you are planning to normalise for 24 hours and measure in a temperature-controlled environment using a CMM (which Protolabs offers).

 (# aluminium alloy CTE = 24 µm/m/°C, ambient 18 °C, body temp 37 °C, length 150 mm)

Quality control and documentation

Upon request, we'll measure using CMMs (coordinate measuring machines), laser scanning or other metrology equipment. We will also work with you on the Production Part Approval Process (PPAP), provide a Certificate of Conformance (CoC) to your specifications, and provide First Article Inspections (FAIs), and material data sheets.

Capability and measurement accuracy

'Although Protolabs quoted ±0.1 mm on the aluminium parts we received all of the dimensions were within ±0.05 mm' ' customer comment.

Protolabs uses capability studies to maintain tolerance, which means we often exceed the quoted tolerance, as it needs to cover multiple machining setups and material types. To get the best tolerance, use the following guidance:

• Where possible, orientate all the inter-related features to be machined in one plane (so they get manufactured in the same setup)
• Use materials with a low thermal expansion (Coefficent of Thermal Expansion CTE)
• Use plastics with good hygroscopic properties: water absorption will change the size and shape, this will effect CNC cut glass filled plastics

Geometric Dimensioning and Tolerancing

GD&T provides a more detailed narrative that the designer can use to explain the important manufacturing considerations to the manufacturer. A little like a shorthand ' often by adding a GD&T you are requesting a specific sequence of manufacture, and possibly a different manufacturing process. As this includes the fit relationships between various part features, it also demands more quality control, measurement and gauging.

Limits and fits: Normally defined on a hole basis (to ISO 286-2) this uses a letter and number (along with the overall hole diameter). Holes are defined with a capital letter H7, shafts with a lower case g6. The bigger the number the wider the tolerance band:

• 9 and above is a typical mill or drill tolerance,
• 7 generally means a reamed hole: a specific reaming tool is needed for each hole size
• 6 and below needing even more specialist machining.

The letter defines how far from nominal (H is on nominal, k and greater are larger than nominal (interference fit) g and lower are smaller than nominal (clearance fit).

GD&T:

A good course will explain both how to use and measure each tolerance class (there are plenty to choose from, Mitutoyo, ImechE or NPL). How are Geometric Dimensions & Tolerances manufactured?

True position: Most commonly used with a diameter symbol to show the tolerance applied in every direction. Note it is absolute, so 0.030 means ±0.015. Reamed holes are almost always needed, as if the hole diameter is irregular it will eat into the GD&T. Calibrated CNC equipment and meticulous measure-setups are required.

Flatness: Milled surfaces are generally quite flat. Adding a very tight flatness is normally code for surface grinding. Adding parallelism means two faces must both be flat to each other. Surface finish is often also added (as it will eat into the measurement tolerance). Tip: slightly raised pads or marking the drawing to show only the areas where flatness is critical can simplify manufacture and measurement.

Cylindricity, concentricity and run-out: applies to holes and shafts, run-out is most often specified as it is easier to measure: a 'clock' or DTI (Dial Test Indicator gauge) measures deviation as the work piece is turned. It is a compound measurement so further measurement may be required to work out if it is cylindrical (not egg-shaped) or concentric (off the centre of rotation).

Squareness (perpendicularity and angularity): CNC milling machines are calibrated to check the tools are square to the machining bed, this delivers good squareness, especially over short distances. The tighter the squareness tolerances the more iterative and time consuming the manufacturing will be.

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