CFRPs are produced from carbon fibers and thermoplastics or thermosets to create a final product with a high strength-to-weight ratio. Due to the varying requirements of these combined materials, they are also susceptible to internal stress, oxidation, degradation from excessive heat, and delamination at cut or drilled edges. A coolant might be applied with other materials, but coolants can cause shrinkage and cracks to develop in carbon-filled polymers as time goes on. For CFRP materials, utilizing an annealing process can reduce the risk of cracking, wear, or other performance degradations.

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Similar to glass-filled plastics, carbon fiber reinforced composite machining is no easy task. However, by ensuring you have the correct machine setup, taking the time to contain dust, and understanding the characteristics of CFRPs, you can successfully manufacture precision components with complex geometries.

When milling or drilling, or creating a tool path for a CNC machine the feed rate must be determined. Materials have rated surface speeds for a given type of cutter. The harder the material the slower the speed. Given the diameter of the tool and the surface speed, the RPMs of the spindle can be calculated. Then if the tooth load for the cutter is know, and the number of teeth, the feed rate can be determined.

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Before beginning any carbon-filled plastic machining process, we recommend consulting an experienced machinist to avoid costly mistakes or unwanted outcomes.

Carbon fiber reinforced plastics or polymers (CFRP) feature low density, high strength and stiffness, good toughness, and good resistance to creep, fatigue, wear, and corrosion. They have a low friction coefficient and can meet most dimensional tolerances, surface quality specifications, and other requirements. These characteristics make carbon-filled composites popular in many industries, but they are particularly suited to aerospace applications. Yet, for all these advantages, machining carbon fiber reinforced polymers can be expensive and challenging due to several factors.

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Machining carbon-filled plastics produces a large amount of harmful dust. This dust can negatively impact the performance level of your final parts. For instance, dust contaminating an electronic device will severely compromise the device’s capabilities and can cause short circuits or other critical failures. Always conduct CFRP machining in a well-ventilated area and ensure that your employees are outfitted with personal protective equipment. To keep particulates and airborne CFRP dust from impacting your final machined part, seal the machine tool enclosure whenever possible and consider installing a suitable dust collector to your system.

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If your equipment cannot meet these requirements, the best and most cost-effective option is to partner with an experienced machine shop already outfitted for machining carbon reinforced polymers.

The best way to mitigate the challenges in machining carbon reinforced composites is to partner with an experienced machine shop like Upland Fab. We specialize in machining high-quality and reliable industrial parts made from precision plastics and composite materials, working closely with your team to ensure all specifications are met. We machine an extensive range of CFRPs in-house at our California facility, including:

Carbon fiber reinforced polymers are hard on CNC machines and tools due to their abrasive nature. Whether milling, turning, or using a multi-axis CNC machine to cut your carbon reinforced plastic parts, always be sure that you are utilizing the best equipment and processes to produce high-performing final products.