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Carbon Fiber Machining Service
Customized Carbon Fiber Machining Service
CNC machining on CFRP composites with tolerances of ±0.01mm. AS9100D certified. Capable of producing aerospace-grade production components from rapid prototypes.
Looking Over the Material
What is the CNC Machining of Carbon Fiber?
Carbon fiber machining is the highly controlled process of cutting, shaping, and finishing Carbon Fiber Reinforced Polymer (CFRP) composites with the use of advanced computer software. Such materials are made of carbon fibers (5 – 10 micrometers in diameter) in epoxy resin and are advanced composites.
Strength-to-weight ratio
5 times stronger than steel, 2/3’s the weight
Tensile Strength
3 – 7 GPa (aluminum: 0.3 GPa)
Thermal Expansion
Near-zero CTE offers dimensional stability
Corrosion Resistance
Rust and the majority of chemicals have no effect to it
Gallery of Custom CNC Machined Carbon Fiber Parts
View our collection of personalized CNC-milled carbon fiber components. Check our exemplary precision craftsmanship in several sectors and industries.
Precision CNC Machining Processes
Advanced machinery with specialized tools dedicated to working with carbon fiber composites.
CNC Milling
3/4/5 axis precision milling to create complex geometries.
5,000 to 15,000 RPM.
CNC Drilling
Polycrystalline diamond tooling to create holes, eliminating delamination.
3,000 to 5,000 RPM.
CNC Turning
Production of cylindrical components requiring tight tolerances.
±0.025 mm accuracy.
Waterjet Cutting
Cold cutting for applications involving heat-sensitive materials.
±0.23 mm tolerance.
Routing and Trimming
Finishing edges and cutting to shape.
Less than 0.8 μm roughness finish.
5-Axis Machining
For complex multi-surface geometries, reduced setups by 60%.
Reduced setups by 60%
Types of Carbon Fiber Grades
Select a material grade according to your application specifications and budget
Standard Modulus
$
Modulus
33-36 Msi
Common Types
T300, T400
Best For:
General industrial, sporting goods
Intermediate Modulus
$$
Modulus
42-47 Msi
Common Types
T700, T800
Best For:
Automotive, aerospace secondary
High Modulus
$$$
Modulus
57+ Msi
Common Types
M40, M46, M55
Best For:
Aerospace primary, satellites
Can’t Decide Which Grade to Pick?
Our engineers offer complimentary material selection consultations. We will examine your application specifications, load conditions, and budget to recommend the best grade of carbon fiber.
Applications of Carbon Fiber Machining Services
Custom carbon fiber machining designed to meet the needs of your industry
Automotive & Motorsport
High-performance CFRP parts for EVs, supercars, and racing applications.
30-50%
Weight Savings
Specs
Prototype
5 Days
Standard
IATF 16949
Common Applications
- Body panels & hoods
- Suspension A-arms
- Drive shafts
- Battery enclosures
- Interior trim
- Aero components
Industry Focus
Precision parts for Automotive & Motorsport.
Drones & UAV
Lightweight frames and components for commercial and racing drones.
15%+
Annual Market Growth
Specs
Min Order
1 Unit
Prototype
3 Days
Common Applications
- Quadcopter frames
- Motor arms & booms
- Camera gimbal mounts
- FPV racing frames
- Agricultural sprayers
- Fixed-wing structures
Industry Focus
Precision parts for Drones & UAV.
Aerospace & Defense
Flight-critical components meeting AS9100 and NADCAP requirements.
50%
Weight Reduction
Specs
Tolerance
±0.01mm
Certification
AS9100D
Common Applications
- Fuselage panels
- Wing structures
- Control surfaces
- Interior components
- Satellite structures
- Engine nacelles
Industry Focus
Precision parts for Aerospace & Defense.
Medical Devices
Radiolucent, biocompatible components for imaging and surgical applications.
94%
Imaging Artifact Reduction
Specs
X-Ray Atten.
<0.1
Standard
ISO 13485
Common Applications
- CT scanner tables
- MRI coil housings
- Surgical instruments
- Prosthetic components
- X-ray cassettes
- Patient positioning
Industry Focus
Precision parts for Medical Devices.
Robotics & Automation
Low-inertia components enabling faster cycle times and higher precision.
62%
Inertia Reduction
Specs
Precision
±0.005mm
Environment
Cleanroom
Common Applications
- Robot arm links
- End effectors
- Gripper fingers
- Gantry beams
- Wafer handling
- Pick & place tooling
Industry Focus
Precision parts for Robotics & Automation.
Sports Equipment
Championship-winning carbon fiber components for professional athletes.
5x
Stronger than Steel
Specs
Finish
Premium
Custom
Available
Common Applications
- Bicycle frames & forks
- Golf club heads
- Tennis racquets
- Hockey sticks
- Ski poles
- Rowing oars
Industry Focus
Precision parts for Sports Equipment.
We Solve CNC Carbon Fiber Machining Challenges
Working on carbon fiber requires industry experience and specialization. Here is how we tackle the challenges we face.
Delamination & Fiber Pullout
The separation of carbon fiber layers will jeopardize the strength of the structure.
How We Do It
Using diamond coated tools with optimized settings at a cutting speed of 80-150 m/min.
What We Achieved
Having efficient cooling applied
Rapid Tool Wear
Carbon fiber is 5-10x as abrasive as glass fiber.
How We Do It
Using PCD and diamond coated end mills at a controlled feed rate.
What We Achieved
10-20x longer tool life than carbide.
Heat Buildup
The low thermal conductivity of carbon fiber will degrade the resin.
How We Do It
Using internal coolant systems combined with a climb milling strategy.
What We Achieved
Preventing thermal damage to the matrix.
Conductive Dust Hazards
5-10μm particles may be respirable and also conductive.
How We Do It
Using HEPA filtration for wet cutting and full enclosure.
What We Achieved
A dust capture rate of 99.66%.
Carbon Fiber Machining Cost Consideration
We believe in transparency when it comes to pricing. Here are the factors that affect the pricing of your project.
30%
Material
Sheets/tubes of carbon fiber raw
25%
Tooling
Cutting tools with diamond coating
35%
Labor
Time of a qualified machine operator
10%
Overhead
QC, Equipment, Location
Real Projects. Real Results.
Carbon Fiber Machining Case Studies
Improving your business with proven engineering success stories.
Satellite Antenna Brackets
Tier-1 aerospace supplier for NASA faced a 40% delamination rate when drilling M55J high-modulus carbon fiber. Required ±0.008mm positional tolerance on 48 mounting holes.
Our Solution
- Custom PCD drill bits with 130° point angle.
- Through-tool coolant at 70 bar pressure.
- Proprietary PEEK backing plate system.
- Optimized parameters: 8,000 RPM, 0.04mm/rev feed rate.
0%
Delamination Rate (Down from 40%)
±0.006mm
Achieved Tolerance (Exceeded Spec)
100%
First-Pass Yield
35%
Cost Reduction
“The zero-delamination achievement on M55J material was something we thought was impossible. These brackets are now orbiting Earth on two communication satellites.”
Racing Suspension A-Arms
Replace aluminum suspension arms with carbon fiber to reduce unsprung mass. Must withstand 15G lateral loads. Deadline: 3 weeks.
Our Solution
5-axis single-setup machining (60% cycle time reduction), diamond reaming for Rz 1.6μm bearing bore finish, and DFM collaboration to optimize ply stack design.
47%
Weight Reduction (680g vs 1280g)
18G
Tested Load Capacity (120% of req)
-3 Days
Delivered Early
P3 Podium
Team’s First Podium Finish
“The unsprung weight reduction transformed our car’s handling. Zero play on bearing interfaces after a full race weekend.”
Agro Drone Frames
Scaling from 50 to 500 units/month. Previous hand-cut frames had 12% field failure rate. Target cost: $85/unit.
Our Solution
Nesting optimization (8 frames vs 5), Diamond Compression Routers to eliminate delamination, material switch from T700 to T300 (sufficient stiffness), reduced cycle time to 12 mins.
99.2%
Quality Yield (vs 88% prev)
$72.00
Unit Cost (15% Under Target)
0.8%
Field Failure Rate
500+
Monthly Capacity Achieved
“Our field failure rate dropped from 12% to under 1%. The cost savings allow us to compete with overseas manufacturers.”
CT Scanner Patient Table
Replace aluminum with carbon fiber to reduce X-Ray Scatter. Support 250kg weight with <0.5mm deflection. FDA documentation required.
Our Solution
T800 carbon fiber with phenolic resin (low attenuation), foam core sandwich construction, waterjet trimming, and complete FDA data package.
94%
Decrease in Artifacts
0.08
X-ray attenuation (Spec < 0.1)
0.3mm
Deflection at 250kg
Cleared
FDA 510(k) First Submission
“The improvement in image quality was noticeable right away. We received FDA clearance on the first submission.”
Pick & Place Robot Arm
Reduce cycle time from 120 to 180 cycles/min. Aluminum arm inertia caused motor overheating. Required ±0.02mm repeatability in cleanroom.
Our Solution
Hollow box section (FEA optimized), quasi-isotropic layup, 5-axis machining for ±0.005mm interface tolerance, and sealed surface finish.
62%
Inertia Reduction (180g vs 475g)
240Hz
Natural Frequency (Spec 200Hz)
±0.015mm
Repeatability at 180 cycles/min
4 Months
ROI Achieved
“Drop of 15 degrees in motor temperature… Carbon fiber arms have been ordered for twelve additional machines.”
Interactive Engineering Toolkit
Estimate costs, compare materials, and calculate weight savings instantly.
Estimated Price Range:
$-.–
*Estimate includes material & labor. Setup fees may apply.
Get an Official Quote →
Recommended Grade:
T300 Standard
Standard modulus carbon fiber. Best for general industrial use, cosmetic parts, and basic structural components.
Request Material Datasheet →
Standard Machining Tolerances
| Feature | Standard | Precision |
|---|---|---|
| Hole Diameter | ±0.05mm | ±0.01mm |
| Profile / Contour | ±0.10mm | ±0.05mm |
| Flatness | ±0.10mm | ±0.03mm |
| Depth | ±0.15mm | ±0.05mm |
Recommended Cutting Parameters
| Process | Speed (RPM) | Feed Rate |
|---|---|---|
| Drilling | 3,000 – 8,000 | 0.02 – 0.08 mm/rev |
| Milling | 80 – 150 m/min | 0.05 – 0.1 mm/tooth |
| Routing | 10,000 – 18,000 | 2 – 5 m/min |
Carbon Fiber Machining Service FAQs
Carbon fiber is anisotropic and abrasive, therefore fully CNC machining carbon fiber is different from metals. To avoid encapsulation, overheating, and delamination, tool selection, spindle speeds, feeds, and cutting strategies must be optimized. Moreover, the use of diamond or carbide tooling materials, specialized chip evacuation systems and high feed rates with shallower cuts are more common in carbon fiber machining. Moreover, carbon machining is different as it focuses more on the containment of fiber dust for health and eSD considerations.
Carbon fiber design requires specific design considerations with respect to the ply orientation, stacking sequence, and design tolerances to account for the composite’s directional stiffness. Designers must consider the potential for high springback, tooling marks, edge delamination, and of course, springback, when tight tolerances are specified for post-cure CNC finishing. More positive outcomes can be expected when it is specified to avoid sharp edges around holes, to add reinforcements around bearing surfaces, and to plan on secondary machining.
CNC machining of high-performance carbon fibre components yields the high precision and reproducibility of geometry and surface finish to the exacting tolerance levels required for the aerospace, motorsport and medical sectors. CNC machining allows for the addition of complex features with extreme precision and alignment of holes, as well as a high consistency of part-to-part repetition, all while reducing the requirements for manual labour. Due to the adjusted machining parameters, the mechanical properties of high performance carbon fibre laminates are not compromised.
CNC machining of carbon fibre requires the installation of a dust extraction and HEPA filtration systems and the use of appropriate PPE as carbon fibre dust is hazardous to inhale and is electrically conductive. Work processes should incorporate systems of localized vacuum containment around the cutting tool, regular servicing of filters and surface grounding to mitigate the risks of static charge. Procedures for the disposal of contaminated cutting fluids and scrap remain within the boundaries of the applicable legislation.
Common post-processing includes edge sealing with epoxy or resin coat, sanding or buffing, and the inspection of edges for delamination or of fiber exposure. If aesthetic or operational requirements dictate, the parts can be painted, clear-coated, or assembled. For critical parts, non-destructive testing using ultrasound or tap testing can assess integrity.
Increased costs and lead times are to be expected when working with carbon fiber. This is primarily due to the need to implement special machining processes for the layout, curing and other processes particular to working with carbon fiber. On the other hand, the carbon fiber will allow for the removal of a number of heavy metal components and/or other such components in a given design due to the being able to achieve the desired goal at much lighter weights, and therefore, much more efficient designs. The total cost is dependent on volume, the number of parts required, complexity, and any special touches that are required.
Diamond-coated or solid carbide end mills with polished flutes tend to work best due to their extreme wear resistance and sharpness. Higher feed per tooth and reduced radial engagements work best moderate spindle speeds to produce shearing rather than abrasive rubbing while disengaging the fiber. Toolpath planning using climbing milling and multiple light passes will help reduce tool wear and delamination.
5-axis CNC machining should be utilized when considering parts with intricate geometries, multiple faces, or parts that need tighter tolerances than a 3-axis CNC mill can do with multiple set-ups. 5-axis machining helps to mitigate re-positioning, which can be a source
These include the need to be sensitive to the cut direction in relation to the fiber orientation, the need to try to avoid edge delamination, and the difficulty in achieving deep internal features that do not have some form of specialty tooling. If there is a thick laminate stack, it may require a two-step (progressive) process to thin down the laminate or to do some punching. Some ultra thin, or flexible, prepregs may be difficult to retain during the machining process. The impact of these limitations can be minimized by engaging .
Ready to Start Your Carbon Fiber Project?
For an immediate quotation, please upload your CAD files, and within one day, our engineers will assess your design and issue any relevant DFM observations.
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