Aluminum 3003 is nearly pure but does contain the mineral manganese. It is a non-heat treatable alloy, ideal for making items used in the kitchen like cooking equipment and utensils, as well as chemical equipment, roofing and siding.

At Protech Composites, we make carbon fiber sheets that can be cut with a wide range of standard tools and don’t necessarily need specialized tools for cutting, shaping, and working.

Power Tools: Abrasive Cutting Wheels (Angle Grinders) Angle grinders equipped with metal cutting wheels can be highly effective tools for cutting through carbon fiber quickly and efficiently. Power tools like these can be highly effective at cutting carbon fiber because they oscillate much more quickly than hand tools and produce a clean, accurate cut.

Aluminum is one of the most versatile materials to use for machined parts. It has a high strength-to-weight ratio and is lightweight, making it economical for production use. It is also easy to recycle: According to the Aluminum Association almost 75% of all aluminum previously produced is still in use today.

Other carbon fiber manufacturing companies might offer differing advice on what you can use to cut carbon fiber sheets or panels (given thickness, weave, the type of epoxy resin used, and more). However, some tools are better than others for the purposes of cutting carbon fiber. They can be broadly classified into hand tools and power tools.

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Heat-treatable alloys in the annealed condition are especially strong: after heating, the parts are rapidly cooled, which freezes the metal’s atoms in place. An alloy’s aluminum grade and further processes like those listed above, give aluminum specialized advantages for various utilizations.

In its sheet metal form, aluminum 6061 is one of the best-stamped aluminum alloys for machining. It is often used in metal fabrication including aerospace applications.

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Is Carbon Fiber Dust Dangerous? (And a Primer on PPE) While carbon fiber dust is not toxic, the fibers can be abrasive and the edges of cut panels can be sharp, producing mild irritation to the skin of sensitive individuals. This is why we recommend adequate protection for your hands as well as long sleeves and pants. We recommend wearing a dust mask to prevent accidental inhalation as well. It’s not toxic, but it can be a mild irritant, so you don’t want it on your skin or in your eyes or lungs.

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However, it is important to note a few things. One is that carbon fiber is highly abrasive to cutting edges. Whether you use a craft utility blade, or metal cutoff disc to make cuts, you’ll need to replace it frequently because the cutting edges will probably wear quickly.

This type of manufacturing method is extremely accurate and precise, offering different surface finishes and often using special tooling to handle metals like aluminum.

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The other is that you should also wear personal protective equipment when cutting carbon fiber, regardless of whether you use hand tools or power tools. Always wear safety glasses and gloves to adequately protect your hands. Remove all jewelry. We recommend wearing long-sleeved clothing and long pants made from natural fibers, like cotton or wool. If you’re cutting with power tools, use hearing protection as well. Wear close-toed shoes or work boots.

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Why High-Speed Is a Good Thing We suggest using either a rotary tool or an angle grinder for making cuts to carbon fiber because these operate at high RPM and with precise handling, can be used to make very clean cuts without ripping, cracking, or stressing carbon fiber.

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The 2XXX group is used in the world’s largest automotive, aerospace and transportation industries. The most apparent element used in these alloys is copper, and they are very resistant to fatigue.

In addition to the sporting goods industry, aluminum from the high-strength 7XXX series is used for marine applications, aerospace, defense and transportation. These alloys are so strong, they can become brittle over time. One of the most popularly used alloys in this series is aluminum 7075.

Manual Tools: Bladed Tools (Scissors, Shears, Razor Blades) Thin carbon fiber sheets can be cut with basic bladed cutting tools like scissors, razor blades, and even shears. We recommend using the sharpest possible tools because these will make the cleanest cuts. Avoid heavy tin snips and shears with ridges or “teeth.” These leave clean cuts in sheet metal but can cause cracks and leave stress risers in the epoxy resin of carbon fiber panels.

The 7XXX group is often used for highly–stressed functions and is heat-treatable, ductile and tough. Its major element is zinc but alloys may contain copper, chromium, and magnesium.

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Alloys of aluminum are classified into a wide variety of grades. The grading system helps classify a particular aluminum alloy according to its characteristics. This classification helps engineers and machine shops to determine which alloy is best, based on end-use.

These are probably the most versatile tools overall for cutting carbon fiber products. Use metal cutting discs to make clean cuts in the carbon fiber, on the highest speed setting safe for use with the disc. These tools are also useful because most rotary tools operate at such high RPM that imperfections in the edge or on the surface of carbon fiber panels or sheets can be rectified with very fine sanding or buffing bits.

This alloy is resistant to saltwater which makes it perfect for the marine industry and bridges. Aluminum 5052 is the strongest non-heat-treatable alloy. It is also found in aircraft parts, household appliances and commercial, heavy-duty cooking equipment.

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However, carbon fiber is a conductive material, and therefore you should take care to protect sensitive electronics from exposure to its dust. Always use a good vacuum system or shop vac when cutting or sanding. Choose a well-ventilated area away from electronic devices, as exposure to carbon fiber dust can cause a short in an electrical circuit.

Heat treating is a process in which aluminum is able to be strengthened by increasing its temperature for a set amount of time, essentially baking the metal. There are several kind of heat treatments available including:

It is necessary to have a system of organization for aluminum since so many different alloys exist. Each has unique physical properties like corrosion resistance, strength and ductility. Aluminum grades are classified into seven groups in numerical order, ranging from the 1XXX series to the strongest alloys in the 7XXX series.

Sometimes called “duralumin,” this group has a high strength-to-weight ratio but, due to the copper, is susceptible to corrosion. A commonly used alloy from the 2XXX series is aluminum 2024.

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Although the adaptability of the 6XXX group makes it a top runner for the best aluminum grade for machining, it truly depends on the mechanical properties of the alloy, the end application and the machining processes used. Regardless, aluminum is offered in such a range of options, it will continue to be used as one of the most flexible, economical and strong metals in engineering.

Determining the best grade of aluminum for machining depends highly on what it will be used for. Although not always the case, the following types of aluminum are often paired with the usages below.

In addition to considering the grade of the alloys of aluminum, engineers may also look at whether or not a particular alloy is heat-treatable.

If you require large, or even small volumes of CNC, Swiss precision parts made of aluminum, or any material for that matter, talk to us today and get a free quote.

Aluminum is often used in custom component creation using subtractive, or CNC machining that makes use of cutting tools guided by Computer Numerical Control (CNC) to cut away at a solid.

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Its heat resistance also makes it ideal for secondary treatments and is a great choice if you want the best coating for machining aluminum.

Pure aluminum can be further optimized by mixing it with other elements to create an alloy. Commonly used aluminum alloys often include:

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So are the right cutting tools and techniques. Protech Composites is a carbon fiber manufacturing company that produces high-quality composite materials that will benefit from proper handling, cutting, and shaping. If you have any questions about our carbon fiber products or what tools or techniques would be best used to cut them given your precise application, please reach out to our customer service team at 360-573-7800.

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Power Tools: Rotary Tools Even high-quality rotary tools such as dremel tools are not as powerful or as large as angle grinders, but because of their smaller size and easier maneuverability, they can be used for making very precise cuts and alterations to carbon fiber panels. We recommend solid rim cut-off disks.

The major alloys in this group are magnesium and silicon. One of the most versatile of all machinable alloys is aluminum 6061, which is available in sheet, plate and extrusions.

Aluminum makes for an excellent machining metal partly due to its ability to be easily shaped and cut. Tooling tends to last longer, which translates to cost savings for manufacturers. One of the best tool coatings for machining aluminum is diamond since it performs well at high speeds, although there is significant cost up-front.