Milling for composites and carbon

Composite materials like carbon fiber, fiberglass, honeycomb, Kevlar, graphite, PCBs, and fiberglass have become indispensable across numerous industries. They offer a unique combination of strength, lightweight properties, and durability, making them ideal for applications ranging from aerospace and automotive to shipbuilding and sporting goods.

Milling composite materials requires specialized tools. These fiber-reinforced materials are not only hard and abrasive but also susceptible to delamination and fraying if processed incorrectly. That's why our product range includes a carefully selected series of milling cutters specifically designed for the precise and durable processing of composites and carbon. Whether you are producing in series or looking for maximum tool life, Veldman Tools always has the right cutter for every application.

Which cutter do you use for composites?

The various composite materials—such as carbon, fiberglass, Kevlar, sandwich panels, or epoxy-bonded materials—offer excellent strength-to-weight ratios but also place high demands on machining processes. For a clean, splinter-free finish on composites and carbon without excessive tool wear, specially designed composite cutters are essential. Fortunately, our product range offers a wide selection of specialized composite cutters, so you'll always find the perfect solution for your specific machining needs.

Composite cutters with coating

Several composite cutters in our product line feature a high-quality coating that is essential for a longer tool life on your CNC milling machine. These special coatings, such as Diamond-Like Carbon (DLC) or TiAlN, increase the hardness of the cutter and significantly reduce friction when machining composites. This not only extends the lifespan of your milling tool but also reduces heat generation, which is crucial for an extra-clean, splinter-free end result.

Milling for carbon

Like with other composites, milling carbon requires precision and the right tools. Carbon is known for its unprecedented strength-to-weight ratio and demands specific requirements during carbon milling. Due to the hard and abrasive fibers, tool wear is a common problem, as are delamination and frayed cutting edges. That's why our product range includes specialized carbon cutters that are specifically developed for milling carbon. Solid carbide cutters with special coatings are often used for milling carbon, as they significantly extend the tool's lifespan and ensure a clean, splinter-free finish. The correct cutter geometry, such as a herringbone pattern, is crucial for optimally cutting the fibers and minimizing delamination. Our carbon cutter with coating is the best choice for milling carbon.

Problems that can arise when milling composites

Composite materials consist of different components, usually fibers embedded in a resin, that are combined to create superior properties. While these materials are strong and lightweight, their unique structure makes milling them a challenge. When milling composites with the wrong tools, the following problems can arise:

• Abrasiveness: The fibers, especially carbon and glass fibers, are extremely hard and abrasive. This leads to rapid wear of standard milling tools, resulting in shorter tool life, higher tool costs, and reduced product quality.

• Delamination: This is likely the biggest challenge. During milling, the different layers of the composite material can separate. This is caused by cutting forces that pull the layers apart, leading to structural weakness and visual defects.

• Fiber breakage and fraying: Incorrect milling parameters or unsuitable cutters can lead to frayed edges and unwanted fiber breakage, which compromises the appearance and functionality of the workpiece.

• Heat generation: Composites often have low thermal conductivity. The heat generated during milling can accumulate and damage the resin matrix, leading to delamination and poorer surface quality.

Fortunately, the problems mentioned above can be solved by choosing cutters that are specifically developed for milling composite materials, allowing you to work more efficiently and achieve a superior final result.

Questions about composite milling?

If you have specific questions about milling composites or want to know the right composite cutter for your project, don't hesitate to contact us. Our experts are ready to provide you with personalized advice and the best solutions for all your composite machining challenges.