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I asked on the hobbyist machining board on how to cut carbon fiber. This was the answer I got:

"Composites are very tough on bits. I would suggest a carbide diamond cut router bit, the type they make for circuit board work. If you are going to be cutting a lot of it then it would pay to get the ZrN coated bits. Take a loot at: http://www.soigeneris.com/precisebits_d ... tails.aspx (my web site). A good starting point is to feed 1IPM per thousand spindle RPM, for example 10,000 RPM spindle feed at 10IPM. A 1/16" bit can cut through 1/16" FR4 (fiberglass) in a single pass."

Maybe this will help.

SOURCES

http://www.precisebits.com/products/car ... router.asp

I don't work with carbon fiber, but if I did, these bits might be a good way to machine it. The individual bit prices are reasonable, but with a $50 minimum order, it would be best to place a group order.

how would the diamond coated bits work in this case!

are you using a router or a milling machine?

The guy was recommending it for the mill. My mill is variable speed.

I found one in a grab bag of PC board bit I got at Woodcrafters a long time ago. I tried it. It cut real nicely until I got to the last 1/16" and then a strip of the fiber came up and pulled away.

Just a word of caution when working with carbon fiber materials, especially anything involving cutting or machining wear eye protection, protective clothing and a respirator. Carbon fiber dust or shards are extremely bad for you body. I got this info straight from a friend who works with it everday at BAE in the UK. He says it's just nasty stuff. :)

Good warning. I have decided it is not worth it for weight savings but on for reinforcement which means minimal cutting.

If you are just cutting plates, just use a dremel and cutoff discs. I made lots of R/C chassis way back in the early/mid 80's that way.

On dangerous materials you can keep a running shopvac's nozzle close to your cut to suck up the powder as the piece is being cut. A few short strips can strengthen a plastic chassis immensely.

I've used it for reinforment on chassis', the smaller thin stuff. I just mark it with a silver pencil and cut it under running water with a razor saw. No dust, no fuss. A shop vac would work as well, I just don't have one. Yet another excuse to go to Menard's. :)