Top Tips for Cutting Carbon Fibre – Without the Complications

Cutting carbon fibre isn’t just about getting through the material – it’s about precision, planning, and protecting both your people and your project. With the right approach, you can avoid common pitfalls and achieve a high-quality finish every time.

Blade choice matters.

The cutting blade sets the tone for the entire process. Diamond-coated and tungsten carbide blades are your best options – they’re durable, precise, and far less likely to wear quickly, saving you from costly downtime and replacements.

Keep an eye on the heat.

Unlike metals or plastics, carbon fibre doesn’t disperse heat well. Excessive temperatures during cutting can lead to delamination or surface burning. Always cut with care and the right speed to protect the integrity of your piece.

Safety is not optional.

Correct PPE – including coveralls, gloves, respirators and eye protection – is essential when working with composites. In addition, proper ventilation should never be overlooked. Use downdraft tables or tool extraction units and ensure all equipment is ATEX-rated to handle the volume of particulate. Carbon splinters may seem minor, but they can cause skin irritation and infection – never skip hand protection.

Preparation is everything.

Mark your cutting lines clearly using a quality tape, such as BAXT T9. This helps maintain accuracy throughout and avoids accidental damage. It’s a simple step that can save hours of rework.

Give yourself a margin for success.

Cut just shy of the marked line – around a millimetre – to leave room for sanding and fine-tuning. It’s a small buffer that offers flexibility and peace of mind during finishing.

Choose your abrasives carefully.

Start with a coarse grit, such as P180, and move gradually to finer options like P400 to achieve a smooth, consistent edge. Rushing through this process or skipping grades often compromises the final result.

Don’t neglect the details.

For holes and intricate shapes, ditch the sandpaper in favour of a fine file. It offers far more control and is better suited to delicate areas. Always work from the high-finish side to maintain the best surface quality.

Finish strong.

A light wax can work wonders on cut edges, helping to mask sanding marks and leave a professional sheen. It’s a simple way to elevate your finish and make your work stand out.

Patience pays off.

The temptation to rush is understandable, especially in a fast-paced workshop. But carbon fibre demands care. Slowing down and working methodically often results in fewer mistakes, less wastage, and a more refined product.

New developments are on the horizon.

At DTC, we’re constantly innovating to support composite professionals. The BAXT CARBONite abrasives range is designed specifically for the challenges of working with carbon fibre – offering premium performance where it matters most. Stay tuned.

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