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VIDEO TUTORIAL

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
Perma-Grit Set of 8 Hand Tools in a Wallet Coarse Thumbnail
SET-8CPerma-Grit Set of 8 Hand Tools in a Wallet Coarse£56.66 /each

Perma-Grit Sanding Block Large Thumbnail
SB280Perma-Grit Sanding Block Large£22.92 /each

19mm + 32mm Cutting Discs with Arbor Thumbnail
RD319mm + 32mm Cutting Discs with Arbor£14.58 /each

Safety Glasses Thumbnail
PP-SGLSafety Glasses£3.50 /each

Perma-Grit Bosch/Makita Jigsaw Blade Thumbnail
JSB1Perma-Grit Bosch/Makita Jigsaw Blade£4.12 /each

P2 Valved Moulded Disposable Respirator Thumbnail
PP-P2P2 Valved Moulded Disposable Respirator£2.95 /each

P1 Valved Fold-Flat Disposable Respirator Thumbnail
PP-P1P1 Valved Fold-Flat Disposable Respirator£1.50 /each

Safety Goggles Thumbnail
PP-SGGSafety Goggles£3.75 /each

Perma-Grit 152mm Rodsaw with Junior Hacksaw Thumbnail
TC2Perma-Grit 152mm Rodsaw with Junior Hacksaw£5.82 /each

3M Disposable Coverall Protective Suit Large Thumbnail
PP-SUIT-L3M Disposable Coverall Protective Suit Large£3.95 /each

Total £0.00
MATERIALS & CONSUMABLES
Nitrile Gloves - Box of 100 Large Thumbnail
NG-100-LNitrile Gloves - Box of 100 Large£5.50 /pack

Mirka Wet and Dry Combination Pack 10 Sheets Thumbnail
WPFCOMB-10Mirka Wet and Dry Combination Pack 10 Sheets£6.95 /pack

Total £0.00

VIDEO TUTORIAL

How to Cut Carbon Fibre Sheet, Tube and Parts

Introduction

Comprehensive video tutorial into the safety considerations and the best techniques and practices for cutting and shaping carbon fibre sheet, tube and parts (like a bike seatpost). We look at what safety gear is recommended and then what results you can expect from a range of different tools. Once we've cut the edges we also take a quick look at sealing cut edges.

In the video you'll find answers to the following commonly asked questions:

  • Is Cutting Carbon Fibre Safe?
  • Is Carbon Fibre Toxic or Dangerous?
  • What respirator or dust mask do I need when cutting carbon fibre?
  • What's the best way to cut down a carbon fiber seatpost or handlebars?
  • How do I cut and shape carbon fibre sheet to make my own parts?
  • How do professionals trim carbon fibre parts?
  • Do I need to seal cut edges on a carbon fibre part?
  • Can I cut carbon fibre with a hacksaw, Dremel, rodsaw, jigsaw, grinder etc.?
    • This How to Cut Carbon Fibre Sheet, Tube and Parts Video Tutorial will take you through the techniques and steps to assist you in getting the best results in your project.


TUTORIAL BREAKDOWN

Composition

1. Composition

Carbon Fibre is a composite material made up from cured resin and carbon fibre reinforcement. Both these materials have their own risks and considerations which will be covered in the following section.

Safety information

2. Safety information

Our cutting advice section will demonstrate the use of a Hacksaw, Dremel Cutting Wheel, Junior Rodsaw, Angle Grinder and a Jigsaw using various blades on carbon fibre sheet and parts. You will also learn how to cut Carbon Fibre Tube and a Carbon Fibre Seat Post using a rotational cutting technique with power tools and hand tools.

Different cutting tools

3. Different cutting tools

Great finishes can be achieved on cut carbon fibre sheet, tube and parts by using sanding blocks, files, metal working tools and wet and dry abrasive paper - working through the grits to achieve the finish required.

Cutting carbon fibre tube

4. Cutting carbon fibre tube

Our cutting advice section will demonstrate the use of a Hacksaw, Dremel Cutting Wheel, Junior Rodsaw, Angle Grinder and a Jigsaw using various blades on carbon fibre sheet and parts. You will also learn how to cut Carbon Fibre Tube and a Carbon Fibre Seat Post using a rotational cutting technique with power tools and hand tools.

Shaping and finishing

5. Shaping and finishing

Great finishes can be achieved on cut carbon fibre sheet, tube and parts by using sanding blocks, files, metal working tools and wet and dry abrasive paper - working through the grits to achieve the finish required.

Sealing cut edges

6. Sealing cut edges

In some circumstances it is beneficial to protect cut edges and this can be achieved easily by using epoxy resin and a lint free wipe to apply a thin coating of resin to the cut edge.


DISCUSSION (10)

Please share any questions or comments you may have about this video tutorial.


Ronald Brown
Is it possible to cut straight down the line of the carbon fiber tube?
Easy CompositesMatt

Hi Ronald, yes it is. Clearly the strength of a tube that's been 'slit' in this way will be compromised but in principle there's no problem with cutting down the length of a carbon tube. You'll also find that a carbon fibre tube that uses 100% down its length (like a pultruded tube for example) will feel particularly vulnerable to crushing or further splitting when cut in this way but that's really because they're already vulnerable.


Marc Dave Causing
Can you cut carbon fibre sheet with a laser cutter?
Easy CompositesMatt
Laser cutters tend to melt and burn the resin edges leaving a not very neat edge in need of tidying up. Waterjet and CNC routing are the best options automated cutting options for precise and neat cuts.

Michael stein-reeves
How would you go about cutting carbon fiber roll wrap tubing?
Easy CompositesMatt
The information under the cutting carbon tubes section applies equally to roll wrapped tubes as it does pultrusions so follow our advice there and you should be able to cut the tubes no problems.

Luka IJzendoorn
You also can cut in water. For a conk that will be the best option.
Easy CompositesMatt
Yes, agreed, cutting under water is a great way to cut carbon fibre by CNC. You will see either water bath options or water bath modifications for most desktop CNCs, it's a very clean and safe way to avoid the risks of the dust.

patrick roberts
What would be the best way to clean and make a CF shaft/tube slick?
Easy CompositesMatt
Carbon fibre shaft/tube will sand down and smooth really nicely. We'd just suggest using abrasive paper (the grade of which would depend on how much 'texture' you need to take off but in many cases a 240grit paper might be a good starting point. You can then work you way up to finer grits and then finish with a polishing compound like Pai Crystal NW1 Black which you'll find on our website.

samiksha moharana
Can you please give specification of Dremel cutting wheel and hacksaw
Easy CompositesMatt
Both the cutting wheel and rodsaw hacksaw blade are Perma-Grit tungsten carbide coated tools. You can see those tools and other tungsten carbide tools in the Perma-Grit section of our tools category.

DIMPI kumar
Please guide for drilling process and drill bitts type to be used , thanks
Easy CompositesMatt
For most simple drilling operations you can use normal HSS bits. For larger holes, there are tungsten carbide hole saws (check the Perma-Grit range on their website).

BLDJLN
Can you cut carbon fiber on a bandsaw? If possible, how many teeth per inch do you recommend?
Easy CompositesMatt
Yes, certainly. Much the same as you see in this video, the finer the teeth, the better (less fracturing) the cut will be. Therefore, use bandsaw blades designed for metal and you should be looking good.

Cynthia Odell
Looking for a cutting surface like the one you used in the video. Any description of the product so I can locate one would be appreciated. Great video. Thanks.
Easy CompositesMatt
The surface seen was just an offcut of foam block. Any PU foam or Styrofoam block would be suitable.

Justin Rivera
I was wondering how to drill a hole in carbon fiber rod. I have a rod that I need to attach a screw to and I was wondering if I should drill the hole just as you did through the pre-preg.
Easy CompositesMatt
It is the same method really. You ideally need to clamp the rod and use a bench or pillar drill so the drill bit can't slip and slide everywhere. Be aware that carbon does not take threads very well so screwing directly into it is not a good idea.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
Perma-Grit Set of 8 Hand Tools in a Wallet Coarse Thumbnail
SET-8CPerma-Grit Set of 8 Hand Tools in a Wallet Coarse£56.66 /each

Perma-Grit Sanding Block Large Thumbnail
SB280Perma-Grit Sanding Block Large£22.92 /each

19mm + 32mm Cutting Discs with Arbor Thumbnail
RD319mm + 32mm Cutting Discs with Arbor£14.58 /each

Safety Glasses Thumbnail
PP-SGLSafety Glasses£3.50 /each

Perma-Grit Bosch/Makita Jigsaw Blade Thumbnail
JSB1Perma-Grit Bosch/Makita Jigsaw Blade£4.12 /each

P2 Valved Moulded Disposable Respirator Thumbnail
PP-P2P2 Valved Moulded Disposable Respirator£2.95 /each

P1 Valved Fold-Flat Disposable Respirator Thumbnail
PP-P1P1 Valved Fold-Flat Disposable Respirator£1.50 /each

Safety Goggles Thumbnail
PP-SGGSafety Goggles£3.75 /each

Perma-Grit 152mm Rodsaw with Junior Hacksaw Thumbnail
TC2Perma-Grit 152mm Rodsaw with Junior Hacksaw£5.82 /each

3M Disposable Coverall Protective Suit Large Thumbnail
PP-SUIT-L3M Disposable Coverall Protective Suit Large£3.95 /each

Total £0.00
MATERIALS & CONSUMABLES
Nitrile Gloves - Box of 100 Large Thumbnail
NG-100-LNitrile Gloves - Box of 100 Large£5.50 /pack

Mirka Wet and Dry Combination Pack 10 Sheets Thumbnail
WPFCOMB-10Mirka Wet and Dry Combination Pack 10 Sheets£6.95 /pack

Total £0.00

DISCUSSION (10)

Please share any questions or comments you may have about this video tutorial.


Ronald Brown
Is it possible to cut straight down the line of the carbon fiber tube?
Easy CompositesMatt

Hi Ronald, yes it is. Clearly the strength of a tube that's been 'slit' in this way will be compromised but in principle there's no problem with cutting down the length of a carbon tube. You'll also find that a carbon fibre tube that uses 100% down its length (like a pultruded tube for example) will feel particularly vulnerable to crushing or further splitting when cut in this way but that's really because they're already vulnerable.


Marc Dave Causing
Can you cut carbon fibre sheet with a laser cutter?
Easy CompositesMatt
Laser cutters tend to melt and burn the resin edges leaving a not very neat edge in need of tidying up. Waterjet and CNC routing are the best options automated cutting options for precise and neat cuts.

Michael stein-reeves
How would you go about cutting carbon fiber roll wrap tubing?
Easy CompositesMatt
The information under the cutting carbon tubes section applies equally to roll wrapped tubes as it does pultrusions so follow our advice there and you should be able to cut the tubes no problems.

Luka IJzendoorn
You also can cut in water. For a conk that will be the best option.
Easy CompositesMatt
Yes, agreed, cutting under water is a great way to cut carbon fibre by CNC. You will see either water bath options or water bath modifications for most desktop CNCs, it's a very clean and safe way to avoid the risks of the dust.

patrick roberts
What would be the best way to clean and make a CF shaft/tube slick?
Easy CompositesMatt
Carbon fibre shaft/tube will sand down and smooth really nicely. We'd just suggest using abrasive paper (the grade of which would depend on how much 'texture' you need to take off but in many cases a 240grit paper might be a good starting point. You can then work you way up to finer grits and then finish with a polishing compound like Pai Crystal NW1 Black which you'll find on our website.

samiksha moharana
Can you please give specification of Dremel cutting wheel and hacksaw
Easy CompositesMatt
Both the cutting wheel and rodsaw hacksaw blade are Perma-Grit tungsten carbide coated tools. You can see those tools and other tungsten carbide tools in the Perma-Grit section of our tools category.

DIMPI kumar
Please guide for drilling process and drill bitts type to be used , thanks
Easy CompositesMatt
For most simple drilling operations you can use normal HSS bits. For larger holes, there are tungsten carbide hole saws (check the Perma-Grit range on their website).

BLDJLN
Can you cut carbon fiber on a bandsaw? If possible, how many teeth per inch do you recommend?
Easy CompositesMatt
Yes, certainly. Much the same as you see in this video, the finer the teeth, the better (less fracturing) the cut will be. Therefore, use bandsaw blades designed for metal and you should be looking good.

Cynthia Odell
Looking for a cutting surface like the one you used in the video. Any description of the product so I can locate one would be appreciated. Great video. Thanks.
Easy CompositesMatt
The surface seen was just an offcut of foam block. Any PU foam or Styrofoam block would be suitable.

Justin Rivera
I was wondering how to drill a hole in carbon fiber rod. I have a rod that I need to attach a screw to and I was wondering if I should drill the hole just as you did through the pre-preg.
Easy CompositesMatt
It is the same method really. You ideally need to clamp the rod and use a bench or pillar drill so the drill bit can't slip and slide everywhere. Be aware that carbon does not take threads very well so screwing directly into it is not a good idea.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

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