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Cutting carbon/foam composite

Cutting carbon/foam composite

(OP)
I have a sheet of rohacell pmi foam sandwiched between two sheets of carbon fiber that I need to cut. My first thought was to use a waterjet but I am worried that the material might delaminate. Does anyone have experience cutting a material like this?

RE: Cutting carbon/foam composite

An abrasive waterjet should work if the sandwich is not too thick. But a diamond blade saw would be a lot cheaper and would also work unless you have curved cuts.

RE: Cutting carbon/foam composite

If you need to make an intricate cut by hand I have used standard band saw blades with the work piece resting on a pedestal.  I hope this helps.

Rob Stupplebeen

RE: Cutting carbon/foam composite

We make similar panels and use diamond saw predominantly for straight cuts.  

RE: Cutting carbon/foam composite

The best is to use high speed diamond saw and cut slowly otherwise it delaminates. I do not recommend water jet unless you have a proper injector (it is very easy to delaminate with common water jets).  

RE: Cutting carbon/foam composite

Diamond 'encrusted' (brazed diamond) stuff works the best for me to prevent de-lamination/de-bonding.

If CNC-ing you can get endmill/router versions.  accuracy is not the best though.
 

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