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Civil engineering: Carbon fiber is becoming increasingly popular in bridges and concrete structures where strength is more important than weight. Because it can be up to ten times stronger than steel, it’s preferred, but as we’ve established, it’s much more expensive to use.

The number of times a fiber goes over and under other fibers is known as the crimp, and the higher the crimp, generally, the higher its stability. But high-crimp carbon fiber means the material won’t be very flexible (known as its drapability) to form intricate shapes or geometry.

Carbon fiber is a fabric mat made of woven fibers and is classed as both a composite and fiber-reinforced plastic. It’s 90% polyacrylonitrile (the carbon precursor) and 10% other precursors, like pitch or cellulose. This material is made by carbonization, oxidation, or graphitization. It’s first cut into the required shape, impregnated with resin, then processed in one of the aforementioned methods. When cured, the result is a lightweight and incredibly strong material with an impressive strength-to-weight ratio.Â

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How to cut dovetail joints with a jig

I do not mark out the angle to cut the tails at. In all honesty, it really does not matter.  I just put the saw on the cut line and lean it a bit until it looks good to me. A lot of people get all bent out of shape about the angle on the tails and it makes no difference in the world at this point as long as it looks good to you.

First, I will rotate the board in the vise 90-degrees and cut down the depth line to remove the chunks on the outside edge. Then, I chisel out the waste the same way I did with the tails.

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Aerospace: Its low weight makes carbon fiber suitable for aircraft fuselage, empennage, nose cones, and rotor blades. When these parts are made from this material, aircraft weight can be reduced by up to 20%—something that saves millions of dollars in fuel.Â

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Military/defense: Drones, helicopters, jets, and transport aircraft can all be made using this material. The design of helmets has become much more complex over the years—something that also makes them heavier. Carbon fiber is here to save the day (but there’s still the issue of difficulty detecting damage).

Types of dovetail joints

For most people, you are not going to get it to fit right off the saw the first time. Once you put the two boards together, you will see places where they are tight or overlapping. I use a chisel to slowly remove material until the fit is tight. Be sure to not remove material from any edge that will be a final show edge. You can remove material from either the pins or tails. Give it a try and see what it does. I will often remove material from both. This way you can maintain a tight show face. Remember less is more. This is the make or break step where the skill is developed. If you take off too much too fast you will have large gaps.

My cork position is not at all close to the middle, and no matter how much I try, I just cannot get it to move. What should I do?

This material is infamously expensive. It’s both lighter and stronger than steel, but its high cost puts manufacturers off from using it unless absolutely necessary (kind of like that pricey fragrance you’re saving for special occasions). But now the price of carbon fiber has gone down, and its usage up! Carbon fiber’s days of waiting for high-profile tasks are over; it’s now made into tools and fixings, springs and wires, and can even be used to reinforce tires. You can see a part made from this material in the image below.

Marine: As carbon fiber’s price is on the decline, it’s starting to replace the use of fiberglass in yachts and small boats.Â

How to cut dovetail joints with table saw

Medical: X-ray devices and implants are made from carbon fiber mainly because it is radiolucent (X-rays can pass through it easily). It’s also wear-resistant and has a similar stiffness to human bone. Unlike the metal used in some implants, carbon fiber is brittle and could shatter.

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After going back and forth with the fitting process and testing the fit, you will eventually have a fit that works. It should require a bit of force to put together and be a bit of a struggle to take apart. Remember this is not a skill that can be developed overnight. The more you do it the better it will get.

The carbon fiber that’s used in manufacturing today has a tensile strength of around 4,000 MPa and a high modulus of 400 GPa, making it useful for a whole host of things (not just bulbs). It’s resistant to creep, fatigue, chemicals, and corrosion, as well as nonflammable and nontoxic. With the right treatment, it can be electrically conductive.

How to cut dovetail joints with a router

For more info on carbon fiber, feel free to reach out to one of our reps, or request a free no-obligation quote for any one of our manufacturing services, like CNC machining, 3D printing, and laser cutting, to name just a few.

Because of its high price tag, carbon fiber is currently only used in high-performance applications, a few of which we list below.

Sporting goods: It’s used to make lighter, stronger, and faster-moving tennis rackets, skis, snowboards, bikes, and golf clubs. Just be prepared to pay a lot more for carbon fiber sports equipment.

The aerospace industry is using 3D-printed carbon fiber parts to some extent. Because of safety regulations, any new technology or materials need to undergo extensive testing and qualification before being used in aerospace, but for now, it’s not uncommon to find parts for brackets and specialized tooling made from 3D-printed carbon fiber. Companies don’t have to deal with huge lead times, either.

Dovetail cut

I start with a chisel set back about 1/16" or so from the depth line and make a quick down stroke along the line. Then, come in at about a 30-degree angle and pare back to the stop cut that was just made. Then, repeat the presses tell you are down about half way. Next, flip the board over and do the same thing from the other side until you break through. Lastly, I put the chisel right into the stop line and clean out the wood right back to the line under-cutting the joint slightly for a better fit.

For the depth of the pins and tails, I like to use the actual thickness of the board rather than a marking gauge. This is far more exact, and it requires fewer tools. On top of that, there may be small differences from board to board. This will give you exact measurements to use. To make these marks, I set them on the back side of the Moxon vise and make the mark on both sides of the board. It is fairly quick to mark both sides of both boards and you are making a line that you can trust.

Cutting dovetailsfor beginners

I like to use a storyboard to transfer the marks to the end of the board. This way, I can make the same tails on all the boards. Then with a square, I transfer those marks across the top square to the face of the board. Make sure to cross or (x) out the segments that need to be removed. It is no fun to cut out the wrong pieces.

This type of fiber’s high heat tolerance was what inspired Sir Joseph Wilson Swan to use it for an incandescent lightbulb in 1860. Back then, carbon fiber filaments weren’t as strong as they are now, so when tungsten came onto the scene, it pretty much took over in the lightbulb-making department. More than 50 years went by without carbon fiber being really used for anything, but a stronger version was brought out in the 1960s, and Rolls-Royce snapped it up for its jet engines—despite the brittleness thing.

Energy: Plans for carbon fiber battery storage systems are in the works, which could greatly reduce the weight of electric cars.

Single dovetail joint

Cutting dovetailsby hand

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Carbon fiber, a.k.a. graphite fiber or carbon graphite, has become a firm favorite in several sectors, and for good reason. But we won’t give it all away in the intro: read on to find out what this material is, its different types, and what it’s used for.

One downside, though, is something called Barely Visible Impact Damage. Basically, it’s hard to spot damage on this material with the naked eye, so checking for faults needs extensive training and testing. This factor affects most of the above industries, but especially aerospace, energy, marine, and military.

Carbon fiber is compatible with 3D printing. It can either be used as a continuous fiber layer or printed as short strands in the filament of an FDM (Fused Deposition Modeling) printer. The printer will need two printheads if you are to print with a continuous fiber: one for the plastic filament and one for the carbon fiber. If you choose to embed chopped strands within the filament, you can improve the strength and stiffness of printed parts without going bankrupt. Using this material in 3D printing means you can make parts that can be used for structural purposes because they’re way stronger than the typical PLA and ABS used in 3D printing. With carbon fiber, parts can be compared in strength to materials like aluminum.

Sometimes I will use the square to put vertical lines down the face of the board to follow with the saw, but most of the time I just use the reflection in the saw to make sure it is square to the face. Next, it is time to just cut. Keeping the reflection flat to the work piece, I cut down to the depth cut line.

Dovetails can be complex, but they do not need to be. This is the simplest and easiest way I know to hand cut a dovetail joint. As hand tool woodworking skills go, this one is very easy once you master a few basic skills. Also, there are thousands of ways to do it. This is just one method that does not require much thought or a pile of jigs.

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Set the pin board in the Moxon vise just slightly above the top of the vise and with a block the same height as the Moxon vise so you can set the tail board on top and line them up. While keeping pressure on the board, use a marking knife and transfer the marks to the end of the pin board. Again, make sure to cross or (X) out the segments that need to be removed.