How to Cut Carbon Fibre Sheet and Carbon Fiber Parts (Technique & Safety)

Very detailed guide to cutting and shaping carbon fibre sheet and carbon fibre parts (like a seat-post). In this guide we dispel some myths surrounding cutting carbon fibre (no it won't kill you) and demonstrate exactly what you can expect when cutting different types of sheet, tube and parts using a range of common workshop tools.

[@tnt9062]

The fact that these guys are still recording for us such professional videos in 2021 confirms that the safety advices work :) Thanks!

[@easycompositestv]

Appreciate the comment Yury, hopefully many more years of videos are still to come :)

[@colbywan]

This is the most thorough carbon fiber cutting video on the net.

[@bigtoeflip]

Literally.

[@easycompositestv]

Thanks for all the feedback people; it makes us want to keep producing these videos. We have something very exciting in the pipeline now (another big 'project' similar to the bonnet/hood) which I think will really inspire people. Lots of filming and editting to do yet but stay tuned in....

[@Juvodotorg]

Thank you so much for this video! Spent hours looking at all these other videos without any answers, only to serendipitously click on this video and have all the answers laid out right in front of me. Thank you so much!

[@easycompositestv]

Its our pleasure and glad we could be of some help!

[@andrewwilson8317]

I work an an engineer on carbon fibre aircraft and would like to recommend the cutting tool I prefer to se to work on the aircraft. I use a Fein multimaster oscillating cutting tool with a bonded diamond blade. Cuts beautifully and you can cut very close to finished size. Bonus is it can be used for finishing too.

[@tomasescobargallardo6579]

That's an electric tool, how do you do with the dust/explosive atmosphere?

[@Alhussainba]

@@tomasescobargallardo6579 I have seen few that use a vacuum cleaner close to the cutting so all fibres dust gets trapped inside the vacuum bag.

[@easycompositestv]

Thanks David; it's a great product, you'll get on really well with it. Of course we're all here if you have any questions or problems.

[@georgedumbrava2435]

Thank you so much for this wonderful and comprehensive presentation 🙏 I wish you the best life and all the success in future career ♥️

[@easycompositestv]

There will be a new laminating video coming soon and also a new skinning video (they are two different processes). We've learned a lot over the years, not to mention increased the production values for our videos so replacement videos for skinning and laminating are overdue :)

[@beingmomca2083]

This helped a lot! I'm planning on cutting down the carbon fibre sideguards from my current wheelchair to use on my new one when it comes to match my wheel profile. I wanted to make sure I wouldn't ruin them and this video answered all of the questions I had!

[@easycompositestv]

It's the new Dremel Fortiflex. They used to be called Motorflexes which were amazing until they stopped making them but the good news is they releaunched it, called the Motorflex. Worth every penny (and you can get all replacement spare parts if you use it a lot like we do).

[@Tpwish42]

Answered all my questions. Thank you for a well presented clear video

[@chir0pter]

this is a critically important videos. i think a lot of people start working with carbon fiber thinking it's as safe as arts & crafts and it's really not

[@JBWization]

Such a great detailed visually demonstrated video!! For a kinesthetic and visual learner that I am, this was exactly the information and type of video I was looking for before starting on my carbon fiber project, Thank you so much for the awesome video!!

[@easycompositestv]

You're very welcome. I'm glad it's helped you.

[@seavee2000]

great advice,have had to discover most of this for myself by doing it (for 1/10th R/C car parts) but good to see how the professionals do it-thanks!

[@easycompositestv]

You're very welcome, glad you enjoyed it.

[@chriskluge103]

best instructional on the web!! all the answers in one video great job!!

[@joebrazeau1290]

Thanks very much for an informative, interesting and thorough tutorial. I can finally cut my carbon fiber using my rotary tool and hand saws with confidence.

[@easycompositestv]

I'm glad you found the video useful :)

[@BilalSayedArt]

This is the most informative and helpful video I’ve ever watched. THANK YOU

[@UKMike2009]

Excellent video catering for the hobbyist and low output workshop. Perfect for my needs

[@easycompositestv]

Work through the grits with wet and dry paper. Taking care to remove the scratches from the previous paper. Change the water with each move up the grits to ensure no grit from the previous paper contaminates your part. once you have worked upto 1500 grit, you should be able to polish the part by hand with a polishing compound or by machine, to get a final gloss.

[@easycompositestv]

Thanks! - We can ship to Puerto Rico and for any none-dangerous items shipping is quick and quite reasonable. For dangerous-goods (like resins) it can get a bit complicated and more expensive but most things are possible if there's something you need to source from us. Perma-Grit tools and carbon fibre sheet/tubes etc we can certainly send to you, no problem.

[@rmj134]

I love the videos you guys put together. By far the most informative, and best production quality.

[@PilotPlater]

I was worried I might be getting in over my head without CNC milling capability, this video showed me that carbon fiber is probably easier to work with than metal with the tools I have, excellent.

[@easycompositestv]

Thanks for the comment Andy, glad you enjoyed the video!

[@lindboknifeandtool]

It sands beautifully. Just make sure to have a vacuum or other dust collection under control, and a good respirator. If you’re drilling it, use a 1/16” drill bit for a pilot hole. Otherwise it likes to splinter.

[@miaouew]

Thanks. I'm handmaking a guitar with Rick Toone style carbon plates holding the wooden pieces together (mainly because I don't want to spend 15 thousand dollars on a real RT guitar) and this helped me with my game plan a lot...I don't have a proper workshop and most of my hand crafted guitars have been done with hand tools, but I've never worked with carbon fibre before so I was a little concerned going into it. Not anymore though :)

[@oliverszymanski9743]

Very useful video. Covered everything I need to know. Thank you

[@timgoffard]

Thank you! You just saved me a ton of money having to pay for custom work on a relatively simple project!

[@easycompositestv]

Glad we could help Tim!

[@MAKAWELI187]

Great information on how to do multiple different types of cutting carbon. Thx for your tips sir.

[@terrencepalmer4583]

That is a great demonstration, and very informative. Well done. And to the aircraft engineer mentioning the Fein oscillating diamond cutter. Thanks to the both of you.

[@easycompositestv]

You're welcome Terrence, appreciate your feedback.

[@arvedludwig3584]

I think it's always a good idea to use skin protection creme to avoid any skin irritation. The dust will come off easier or does it interfere with the cut surface, by which I mean damaging the laminate with chemicals.

[@grantjennings162]

Thanks for such a detailed video, answered all of my questions

[@BrianMacDuckston]

I wanted to know a little about cutting and finishing a sheet of carbon fiber. I'd say this video was pretty on point.

[@easycompositestv]

Thanks Brian, glad it helped and answered your questions.

[@saltyguerrilla]

I learned everything I needed to from this one video. Thank you!

[@easycompositestv]

I'm glad it was useful :-)

[@TVtwarn]

Great video Thankyou for this . Material on the way for a small project - this has been brilliant thanks 😊

[@easycompositestv]

Thanks for commenting, glad you enjoyed the video!

[@pf06840]

Very good video. Thorough and gave easy techniques for various carbon fiber materials.

[@shattdbb]

Extremely well made. I know everything I need too now so Thank you

[@minibar7165]

Thanks so much for sharing your expertise in cutting Carbon Fiber, a superb tutorial !!

[@easycompositestv]

Its our pleasure - this is quite an old video now but the tools and techniques are equally as relevant today.

[@charliewhiskey8440]

Best video I've seen yet on how to work on carbon. I image that piece of high density foam isn't cheap?

[@danielnapast4955]

I use a bandsaw, oscilating spindle sander, and a tile cutting saw with a diamond blade to cut and shape parts. If you want to use a bandsaw I would recommend calling Lenox blades and have them recommend a blade for your specific application.

[@prepsandstuff6871]

Thank you I am building a case for my ham radio and want a carbon fiber face plate this helped alot👍👍👍👍

[@easycompositestv]

I'm glad that our video helped your project!

[@ansarogu]

Great video! it answered all my questions and it was very informative, good job!

[@hobie1dog]

Great video, great tripod placement. Thanks for a perfect video.

[@easycompositestv]

Thanks Marty :)

[@pavel9652]

Thank you for such professional video!

[@wikun110]

I highly recommend this video. ONLY thing it lacked was cleaning up drilled holes.

[@easycompositestv]

True enough, we could perhaps have shown that. In reality, just a tickle round with some wet and dry paper is usually all it takes 👍

[@wikun110]

And y’all reply to comments.?..!. Where’s that subscribe button?

[@worldcrafter]

absolutely amazing video, thank you for making this!

[@TheRoundHound]

Excellent video! You answered a number of questions that I had. Will proceed to your website. Thanks.

[@henry2008kim]

Very useful instructions with rich content.. Please do keep them coming!

[@ИванКозьяков-ф9т]

Best video about CF ever! Thank you!

[@bquattrog]

Perfect video, just what I was looking for! Thanks for making it.

[@easycompositestv]

No problem at all, I'm glad the information has helped.

[@SculptyWorks]

Excellent video! Thank you! 👍👍❤❤

[@每日一读-h3f]

Very detailed video that is just what I need, opportunities all my questions. If you can provide under each product purchase brand in that case, we fans won't detour, like carbon fiber cloth, carbon fiber sheet, carbon fiber, and so on, the last time I buy for my car carbon fiber board (brand: fiveeyes) on AMZ, quality are ok, but they only sell carbon fiber board, don't sell other, so need other good quality products.

[@easycompositestv]

Our videos, when viewed through our website, all have a detailed list of products used. The list is too big to be easily put into the limited video description box.

[@mr2ferrari]

great info as usual guys. I just received my easylease today and can't wait to try it!

[@gepgeps]

This video it’s absolutely fantastic! Impressive, really! Thanks for your help! 👍

[@easycompositestv]

You're very welcome Giuseppe.

[@ruperteverhard3631]

Brilliant video and information, all the concerns I had, have been covered! Top Class!! :) ....Thank You ...

[@easycompositestv]

and thanks to you Rupert - feedback like this makes it all worthwhile and makes us want to get more tutorials out there!! :)

[@colinjohnson5515]

Wow. I’m great full to you for this video. Now I have to source some prepreg sheet!

[@easycompositestv]

Well Colin, hopefully you know where to come for that. We’ve been the leading manufacturer of carbon fibre sheet for a number of years, hopefully our quality and price will meet your needs.

[@Learning_Cad_Cam_CNC]

Nice presentation. I kindly request your advice on the methods utilized for cutting in CNC machines.

[@easycompositestv]

If you have some specific requirements you can contact our technical team who will be happy to advise. [e-mail]

[@Learning_Cad_Cam_CNC]

@@easycompositestv Thank you.

[@johnnymckissick2735]

I have learned so much from these videos!

[@easycompositestv]

Hi Johnny, we keep producing videos due to comments like this :) Thanks for the feedback

[@SamLamingMusic]

Great, efficient and very useful video. Thank you very much!

[@dhanashishwarpersadcarbonIsh]

Just love your work Explaining all the way Well done Must watch all YOUR videos 📹 😉

[@easycompositestv]

Thank you for the really kind feedback Dhanash!

[@matthewtinnion]

Myths busted, This has been very helpful. Thanks.

[@monalisa9384]

Very informative, thanks for taking the time to make and for sharing this

[@fetusness]

thank you for this information!!!

[@easycompositestv]

You’re welcome Adrian, glad you’re enjoying it.

[@warmup1705]

Just the video I wanted, great info 👍🏼

[@kenselleck2414]

Thank you for the wonderful video!

[@superdupergrover9857]

IF you are buying a hacksaw, get one with a rectangular frame whenever possible. Older steel tube ones of decent quality work really well. The ones with a semicircular frame like shown here leaves less useful blade length when working on large materials and you cannot use the forward part of the frame as a second handle for the other hand. Also, get one where it can hold the blade at different angles, makes awkward cuts less awkward. Lastly, hacksaws are cheap; spend the extra money to get a nice one. Ignore the bargain bin, spend $10 more and save yourself a lot of time and aggravation.

[@rossagge]

Just what I needed to know. Thanks for this and the other great vids!

[@johartmann9408]

Fantastic Tutorial! Thanks!

[@dcssteve1944]

Great instructional video. Much appreciated!

[@nonono531]

Excellent video!

[@OzReel]

Thank you for this video. Great comprehensive tutorial!

[@flyfishingpiper4976]

Great work guys thank much!!!

[@RodrigoNascimentoMattos]

amazing tut.! please make a how to for carbon fiber tubes!! thanks for this tutorials! i´ve learned a lot!

[@patrickroberts21]

I am extremely happy you made this video, carbon fiber is now used in pool cues and there have been many things said about things that cannot be done without catastrophic results, like even sanding or cutting. I work on cues and have never worked with CF before, So thank you for this video and others I will be subscribing and checking out your website as well. What would be the best way to clean and make a CF shaft/tube slick?

[@easycompositestv]

Hi Patrik, 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.

[@luderickwong]

So, if sand paper is all right, belt sander and drum sander probably all right too? Besides that, if jigsaw with that kind of blade is ok, what if i do the cutting on table saw or miter saw with a metal cutting blade or diamond blade, or even metal cutting bandsaw, is there a minimum speed and blade choice we have to follow?

[@baxrok2.]

Absolutely fantastic! Thanks so much for taking the time to share this info!

[@alexandrealbergaria6224]

that was outstanding - wow! thank you so much for this 30min video. very very cool

[@OverDriveRC]

Great quality video very clear and covered everything very helpful cheers

[@easycompositestv]

Thanks for the comment, glad you liked it :)

[@mohamadfaizmohamadfaiz3784]

very good Caya you explained, I have started learning and have produced carbon for my own use.. I have already repaired my cracked bicycle frame, so I don't need to send it to the shop to repair the crack, the first time I use this carbon, right? my body is very itchy. but from there I started to understand that if it is ready and dry, if it is rubbed, the dust can fly and stick to our body parts..anything, thank you for the way of using this product..very good,,, ,#stay save covid is still there we are almost winning, we have not won against this covid19..#to those who died due to covid condolences to their family members# very grateful for the useful knowledge from you

[@easycompositestv]

Always wear PPE to minimise exposure to the carbon dust when cutting it. It is a respirable dust hazard and can cause minor skin irritation as you found. Washing with cold water will remove any dust on the skin with less irritation.

[@velotegra7156]

Thank you - excellent and useful information, clearly presented!

[@easycompositestv]

You're very welcome, I'm glad you enjoyed it.

[@stevepuffery8918]

Wow, wow great video, everything we wanted to learn is HERE…..

[@easycompositestv]

Hi Steve, thank you for the great feedback! Glad you enjoyed!

[@z1522]

OMG - what is a clear, concise, well-edited and thoroughly professional instructive video doing on the same KZbin we know for hillbilly gasoline substitutes and lizard people warning about the pending collapse of the economic system?

[@swquinn770]

Very informative video and helped a lot, thanks! What would you suggest is the best/cleanest way to countersink holes in CF? And are there any bits you could suggest? Thanks!

[@jamesbarisitz4794]

Diamond bits are my choice. Cone shaped with different grits are available cheap.

[@marksmola7299]

Great, thank you for the education

[@JustinRivera]

Thank you very much for your video, I was also 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. Thank you in advance for your reply.

[@easycompositestv]

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.

[@thek5593]

I would also advise on wearing something long sleeve, there are very tiny shards that itch a lot and you don't want them on you. It irritates A LOT!

[@CarstenFuchs]

And another follow-up question please: How do you know where to cut the hole into the 3D piece? Would the hole be modeled as a depression into the pattern (that is, surface closed from the backside), so that the mould gets a (flat? high?) raise where the hole is, so that the new piece has the guidelines for cutting "built-in"?

[@CarstenFuchs]

Dear team, would you mind telling a bit about *where* to cut and drill? Would the cutting lines and drill locations be modelled as a part of the mould? Or just transferred with pen and ruler from the pattern onto the otherwise flat surface of the new part?

[@BusDriver69]

Any specific cutting disc for my angel grinder? Thanks, great video!

[@easycompositestv]

Standard slitting discs work fine albeit they wear quickly.

[@FiftyPenceR8]

Extremely helpful video, thank you. Now I need to order the permagrit kit!

[@easycompositestv]

Pre-preg carbon fibre will have a specific cure cycle. You need to find out from the manufacturer what that cycle is. The same basic concept of mould making and the basics of laminating are still the same. Also the finishing process is the same. The bagging process for pre-preg has some similarities to other vacuum processes but the bagging stack is unique to the process.

[@adamscottv]

Thoroughly excellent video.

[@larrycrook1593]

Superb video! ✊🏻😊 - Thank you

[@easycompositestv]

Thanks Larry, glad you liked it.

[@crossthreadaeroindustries8554]

Great share, nicely done. Seems I'd want to take the CF dust control to a higher level. The good respirator - I totally agree. But I would seal eye areas because dust gets right into eye fluids. Then, use a shop vac seems bad if CF dust goes through filter and then shot into room's atmosphere. What to do with dust that is collected? Seems to be like nuclear waste, it will always be with us. Dump it out back where it gets into the watershed? I am cautious about this stuff - seems easy to have an incident you won't realize until well down the road when the equivalent of mesothelioma kicks in. There was a lot of loose dust sitting on the foam board after you post-processed the items, to deal with.

[@easycompositestv]

An Air fed mask would be ideal if a lot of material is being cut. Such air feeds need to be filtered as a matter of course. Carbon Fibre Dust itself is not a hazardous material - cured carbon fibre is not generally hazardous - it only becomes a particle hazard once airbourne. Disposal for carbon fibre dust and cut cured carbon fibre is generally in non-recyclable waste, although local rules may differ. If you are careful and wear appropriate PPE, then there is no reason to be concerned about any long term health effects.

[@matts2581]

Totally fresh guys. TY. I am very noob to all of this - TY. :D

[@easycompositestv]

Thanks Matt, glad you enjoyed it.

[@jeffreydanek4833]

Good video but GREAT index on the side. Easy to skip the safety stuff (j/k)

[@dimpikumar78]

Thanks a lot such a detail video. Please guide for drilling process and drill bitts type to be used , thanks

[@easycompositestv]

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).

[@bensonmayfield5636]

Yery good explanations.

[@icebluscorpion]

How about cutting it wet would it be a viable option too? For the drilling perfect holes you should clamp it between two plates of wood and drill through the wood. I think it would work as fine as drilling multiplex/balsa wood by using scrap wood to prevent multiplex/balsa from chipping

[@easycompositestv]

You won't get a neat cut on wet fibres. You can trim the excess off that way but will still need a final trim once cured.

[@OllieCat125]

Appreciate the video very much. Can you provide a link to where I can get these saw and disk blades without teeth. I’ve never heard of there name.

[@easycompositestv]

You can find the Perma-Grit range of products on our website. www.easycomposites.co.uk/perma-grit-tools

[@andymckee53]

Brilliant video guys. Can't wait for the next one. (happy customer)

[@projectitis]

Can you foresee any issues using a high speed router with a small bit (3-4 mm) to cut a hole in a sheet? I need to retain both pieces (cutting out a door).

[@fsociety5696]

tons of great information in this video, thank you

[@MatthieuLibeert]

Great video! Thanks