Is It Safe to Cut Carbon Fiber? Expert Guide to Cutting Carbon Fibre Composites

When it comes to advanced materials like carbon fibers, mastery over their suitable cutting and handling is paramount. In the field, carbon fiber composites are often used because of their great strength-to-weight ratios. These composites are preferred by such industries as aerospace, automotive, or sports equipment manufacturing. On the other hand, cutting carbon fiber entails preliminary planning, the right cutting tools, safety measures, and attention to detail to avoid damage to both the material and the health of the operator. This guide emphasizes proper cutting of carbon fiber composites in such a way that it is safe and yields positive results. As a fabricator whether licensed or skill-based or a civilian DIYer, this article prepares you well so that you can approach the material with confidence.

What are the best methods for cutting carbon fiber?

The optimal techniques for cutting carbon fiber vary for each project as well as the resources available. Most commonly, the following techniques are employed:

Employing a Saw with a Diamond or Carbide Blade

When cutting carbon fiber, a fine-toothed saw blade made out of either diamond or carbide is the best since it ensures a clean and clean finish while also reducing the chance of fraying. These types of blades are usually assembled into jigsaws and circular saws.

Cutting with a Water Jet 

This technique is highly accurate and minimizes the creation of dust, which makes it well-suited for detailed cuts and professional use.

Rotary Cutting Tools

Carbon fiber rotary cutting discs attached to handheld tools are optimal for small and detailed cuts. Rotate the tool with proper control to maintain those edges.

Scoring and Snapping

For thinner carbon fiber pieces, lightly scoring the surface with a utility knife and snapping along the scored line is an easy and inexpensive option.

When cutting carbon fiber, always wear the appropriate PPE such as gloves and a respirator as fine dust particles are generated which can be harmful when inhaled.

Comparing traditional cutting tools for carbon fiber

Cutting tools that are conventionally used for carbon fiber cutting include hand saws, powered saws, and even cutting wheels. The hand saws that take the form of hacksaws with fine-tooth blades are cheap and great for accurate, small-scale cuts, although they are quite hard work intensive. Circular or jigsaws, including carbide jigsaws and diamond-powered saws, are considered power saws, which cut at an efficient speed for larger projects but can create tears in the material without proper skill. Professional applications tend to use cutting wheels, majorly diamond cutting wheels since they provide clean and accurate cuts. There are pros and cons associated with each of these tools, so the decision shifts according to the project’s needs, finances, and resources.

Exploring advanced techniques: laser cutting carbon fiber

Fiber lasers mark an important technological advancement in laser cutting, which continuously exceeds its predecessors. This makes fiber laser cutting a more efficient carbon fiber cutting method as compared to CO2 lasers. This cutting process provides lower operating costs, eliminates mechanical stress on the part, higher speed and power, fine cut edges, and intricate febrics. CO2 lasers are significantly less powerful, suffer from poor beam quality, and their replacement cost is higher than that of pulsed fiber lasers. Therefore, fiber lasers have revolutionized the laser-cutting industry.

Choosing the right method based on your project needs

When considering an appropriate approach to your project, consider a few major factors such as the type of materials, accuracy needed, expected quantity, and total budget. For example, it is common to use mechanical cutting for projects with thicker materials, or whenever a fast output is required. Most CNC routers are appropriate for wood or metal substrates while achieving ±0.005 inch tolerances in most cases, depending on the equipment used.

However, laser cutting has no competition in terms of precision. Laser cutting techniques have tolerances of up to ±0.001, and can easily outperform any other method. They are particularly regarded as ideal for projects with complex designs requiring minimal material, or achieving complex shapes. It’s extremely beneficial in the processing of thin metals and plastics, or composite materials. Research indicates most modern laser-cutting equipment can cut steel sheets up to 0.4 inches thick with excellent edge finishes. This is incredibly important for industries such as aerospace or medical device manufacturing.

Waterjet cutting is a highly adaptable and increasingly popular technique that provides a non-thermal process with no heat-affected zones. This technique is very useful for the cutting of thick and heavy materials including steel, stone, and other composites. Research shows that waterjet systems can cut materials up to twelve inches thick with an approximate precision of +- 0.003 inches which makes them very useful for heavy-duty operations including construction and industrial manufacturing.

While each method offers distinct benefits, much of the work comes down to identifying the goals of your project. By paying attention to details such as precision, material, and production rate, it is easier to select a method that meets the operational objectives, thus enhancing productivity while minimizing costs.

What safety precautions should I take when cutting carbon fiber?

Understanding the risks of carbon fiber dust

The inhalation of carbon fiber dust or skin contact can be injurious to one’s health. Harmful particles are created when fibers are cut or sanded, which can agitate the skin and respiratory systems. To protect one’s self, it is important to wear a mask or respirator, face goggles, and gloves while performing such tasks. One must ensure proper ventilation while working, or even wear an extraction system to filter the dust. To fae avoidance of dust buildup, the workspace should also be cleaned regularly. Taking these measures as well as following others greatly lessen the risk and assist in ensuring a safe work environment.

Essential protective gear for cutting carbon fiber

Working with carbon fiber requires prioritizing safety to minimize exposure to fiber dust and sharp debris. The appropriate personal protective equipment (PPE) is crucial when cutting, trimming, and sanding activities are taking place.

Respiratory Protection

To protect oneself from the inhalation of small particulate matter, it is recommended to use a well-adjusted N95 mask or any respirator of a higher grade, as it serves as a blanket for defending the respiratory organs. Studies indicate that inhalation of carbon fiber dust over an extended duration will potentially cause an autoimmune reaction to the respiratory organs. Hence, the use of these types of masks must follow NIOSH or other acceptable standards for maximum shielding.

Caution should be taken when a cutting blade is in use, for it may cause eye injury. 

Safety goggles designed to avoid headlights with anti-fog, and scratch-resistant coatings are essential to avoid sharp fibers or dusty particles from making contact with the eye during work. Other types of goggles such as wraparound goggles serve as additional protection and cover entrance gaps that particles could exploit.

Hand Protection

Gloves receiving cut protection injury are crucial in the protection of hands dealing with carbon fiber sheets to shield from the sharp edges. These types of gloves come with greater protection but allow sufficient flexibility to use at hand for detailed work.

Skin Protection

For the prevention of skin irritation from exposed fibers, layered, tightly woven long-sleeve garments should be worn or aprons used. Aprons and disposable coveralls with anti-static features are highly recommended to minimize shed and static build-up during processing.

Hearing Protection

During power tool use, particularly when cutting, ear plugs or earmuffs are vital to minimizing hearing exposure to high-decibel noise.

Ventilation and Extraction Systems

Industrial extraction systems are not typically classified as PPE, but they play a critical role in reducing airborne particulates. Local exhaust ventilation results in reduced particulate concentration in the workspace.

By incorporating these protective measures, individual welfare is attained alongside a generally improved environment to cleaner, more contained areas than before. Always ensure ZMS compliance with statutory protection in place about effective and economical loss control measures.

Setting up a safe cutting environment

A secure cutting method requires the use and adoption of relevant new inventions, care for engineering tools, and observance of safety rules. As per industry data, around 70% of cut injuries in the workplace arise from insufficient health measures employed along with imperfect application of hand tools. The prevention phase starts with choosing appropriate tools for cutting as incorrectly fitted or broken tools can elevate the chance of mishaps.

In the same way, the efficiency of cutting devices and techniques needs to have effective fume exhausts such as maintaining proper balance between supply and exhaust with energy recovery systems. In particular, HEPA filters allow 99.99% blockage of contaminants including pollen, mold spores, dust, and other particles to electronegative with a size smaller than 0.3 microns, thus greatly alleviating certain respiratory risks. In addition to this, the workplace must be fitted with noise attenuation devices because the sound level made by industrial cutting machines can easily go above 85 decibels, causing irreparable damage to hearing organs.

To increase working safety, ergonomic devices such as adjustable tool mounts and anti-fatigue mats should be used as they provide less load stress on the person’s body while cutting. In addition, proper policies such as regular equipment checks as well as adequate maintenance ensure that cutting tools function well and do not pose safety risks. Using sensor-based systems to monitor the effectiveness of the tools can assist practitioners in identifying the risks before it get worse.

Focusing on those issues allows the workplace to not only maintain a toxic-free environment but also ensure their workers are protected. It also enhances the efficiency of the site which decreases risk while increasing productivity.

How do I cut carbon fiber sheets without damaging the material?

Techniques for clean and precise cuts in carbon fiber sheets

Advances in cutting carbon fiber sheets and avoiding frays or damage hinge on using the right tools, having proper techniques, and taking care whilst operating. The following list highlights the most efficient measures, tools, and steps to take:

Employ the Appropriate Cutting Tools

Diamond-coated cutting wheels, tungsten carbide instruments, and specialized shears are crafted for optimal carbon fiber handling, and selecting any of these enables utilizing clean and accurate cuts to be achieved seamlessly. Although these require laser cutters which allegedly produce highly advanced cuts. These tools significantly prevent fiber splintering which leads to ensuring uniform edges.

 Cutting Speed and Feed Rate

Achieving appropriate feed rates with a spindle speed of 15,000-20,000 RPM and a recommended cutting rate of 100-350 inches per minute is ideal when using a CNC machine to cut carbon fiber sheets. Achieving this balance prevents overheating the material which ultimately weakens the resin set matrix.

 Use Masking Tape or Clamps

Lastly, using masking tape along the cutting surface prevents relative movement during cutting.

Venting and Dust Management

During a carbon fiber machining operation, a concentrated amount of dust may be created, which can be harmful if breathed in. Therefore, it is advisable to use a vacuum system, or, at the very least, cut the component in a place that is well-ventilated.

Edge Finishing

Polishing compounds can also be employed when they are necessary to achieve added surface smoothness. After cutting, the edges can be sanded with fine-grit sandpaper, which can ensure the edges have no roughness or splinters and are completely smooth and finished.

These techniques along with adequate safety gear measures are critical to the success of the operators by providing the highest quality results without affecting the carbon fiber material structure and appearance.

Avoiding delamination and fraying when cutting carbon fiber

Employ diamond blades or carbide-tipped cutters to prevent peeling or untwisting the edges of carbon fibers. Such tools reduce delamination by reducing stress on the material. Clamp the materials as much as possible to avoid any uncontrolled movements because the actions of cutting can further amplify any fraying. Also, to ensure clean cuts to the carbon composite’s top surface, apply thin tape along the cut line to reinforce the fibers being cut. For optimal outcomes, use moderate cutting speeds with light machinery pressure. It is preferable to prepare the operational steps. Choose the right equipment to maintain proper cutting standards without unnecessary deformation.

Tips for cutting complex shapes in carbon fiber

Employ Accurate Cutting Instruments

Employ devices such as your CNC, a fine-tooth jigsaw, or a rotary tool equipped with a diamond-cutting wheel for delicate and precise incisions.

Support the Material Correctly

Secure the carbon fiber sheet onto a flat surface to hinder any form of movement or flexing during the cutting phase.

Utilize a Pre-Marked Standard

Mark the detailed outline of the shape to get the proper cutout to make the task easier and precision cutting possible, eliminating the risk of defects.

Work in a Precise Manner

Do the incisions at a constant range of speed, do not attempt to go too fast as it may cause issues of accuracy or harm the material.

File the Edges Post-Cutting

Sanding is done with fine-grade sandpaper, do the edges to remove any existing protrusion or lack of evenness.

What tools are best for cutting carbon fiber at home?

Evaluating power tools for cutting carbon fiber

To cut carbon fiber sheets at home, the most effective power tools are the rotary tool with a cutting wheel, a jigsaw with fine teeth, or circular saws that take carbide-tipped blades. Small sections are more suited to detail cuts, so precision rotary tools are ideal. For more intricate shapes, jigsaws are a perfect fit. Circular saws, on the other hand, work best for long, straight cuts on bigger panels. Adjust the speed settings to ensure that the fraying is minimized, and use sharp blades that are specifically designed for composites, and the results will be delightful. Always wear a dust mask to expose you to any harmful dust that will be created.

Hand tools suitable for small carbon fiber projects

Small-scale carbon fiber projects that involve precision and control can be done using hand tools as they can be very efficient. Some plausible examples are:

Utility Knives: The recommended tool for scoring and cutting carbon fiber sheets of less than 1 mm. A knife with a sharp blade gives the most accurate results.

• Sandpaper and Files: Recommended for refining shapes and smoothing edges which includes cutting materials. Make sure to use fine-grit sandpaper, as it will not harm the material.
• Scissors are effective at cutting through these thinner layers of carbon fiber.: Strong composite or heavy-duty scissors can slice the braiding of carbon fiber fabric without fraying. It is advisable to use scissors specifically rated for cutting strong laminate materials.
• Clamps: These are essential when cutting or shaping the material as they hold it firmly in place for added precision and safety.

These tools are fairly simple to work with, reasonably accessible, and can be relied on to deliver outstanding results for intricate or undersized work.

DIY solutions for cutting carbon fiber on a budget

Cost-effective tools and methods achieve a good job when preparing to cut carbon fiber on a tight budget. For straightforward cuts, utility knives serve as a decent substitute. A skilled hand paired with a sharp utility knife can slice through carbon fiber sheets with ease, allowing the materials to snap alongside the blade’s path. This, along with a cutting mat, further guarantees a precise cut.

Also, a regular rotary tool like Dremel is very useful and can cater to a wider variety of shapes. While these tools commonly come at cheap prices, using cutting discs that are designed for composite materials tends to provide smoother edges while also not overheating or fraying. Reinforced carbide or diamond cutting wheels are always the best and most precise options when working with carbon fiber.

Low-income users can utilize a homemade cutting vacuum system for dust management. DIY cutting vacuum systems are less costly and conceal around the workspace, restraining particles from escaping the workstation. Knowing that fine carbon particles are harmful, maintaining an N95-rated dust mask is crucial for safety.

To prepare for cutting, invest in some multi-use epoxy glue or adhesive tape to establish some edge reinforcement. It will help with fabric stability and edge fray reduction to yield cleaner edges using simpler tools. All these methods combined will allow users to work with carbon fiber while remaining safe and budget-efficient.

How can I achieve smooth edges when cutting carbon fiber?

Techniques for sanding and finishing cut carbon fiber edges

To obtain good quality and rounded edges while cutting your carbon fiber, I always recommend using different varieties of sandpaper. In this instance, I recommend using sandpaper of grit 320 to 600 to ensure I have fine-grit sandpaper. EDP or the Edge Dimension Polisher guarantees good sand treatment and evenly distributes pressure. For even better results, I alter the grit used to polish along with applying a thin layer of epoxy to seal the fibers and prevent tearing. Remember, constant vigilance to not overheat is also important as overdoing will damage the structure. Lastly, always use a mask and gloves to decrease the amount of dust particles ingested while sanding.

Using specialized tools for cleaner carbon fiber cuts

To achieve clean and accurate cuts on carbon fiber, requires the use of different tools specifically made for the wood composite. Recommended tools are diamond-coated or carbide-tipped blades because they are very strong and sharp which minimizes fraying. If a circular saw or Dremel tool is being used, blades with fine teeth are preferred because they eliminate the risk of splintering while making the cuts more precise. For even greater control, not only can a water jet be employed, but a laser cutter can be too because both of these tools will cut without generating the heat that weakens the fibers, thus ensuring great precision.

Industry data indicates that the accuracy level that laser cutters can reach is within 0.1 mm at a detail level needed for cuts in aerospace, automotive parts, etc. Securing the carbon fiber cutting part on a stable surface to prevent unnecessary movement that may compromise cut quality is essential for all cutting methods. Besides, low feed rates and gradual shifts in the cutter’s position yield cleaner edges to cuts and enhance the working life of the cutting tool. Employing the aforementioned best practices reduces the amount of waste while preserving the structure of the carbon fiber sheets. Always prioritize safety and use goggles, carbon dust masks, and other personal protective equipment to reduce the risk of carbon dust inhalation.

Preventing splintering during the cutting process

When cutting carbon fiber, ensuring that it doesn’t fracture must be done so that its professional outer finish, as well as inner structure, are well maintained. One possible solution would be using a diamond saw or other blades specially created to be used on composite materials. These tools allow for faster and more precise cuts, thus reducing the chances of fraying. Studies show that shallow cuts are very important since deeper cuts cause stress and increase the likelihood of splintering.

Another effective practical method is using masking tape along the edge of the cutting line to stabilize the fibers. For schematic geometries, cuts can be made at the yarn’s perpendicular axis which decreases the chances of edges splintering. The use of advanced techniques such as cutting with a water jet also provides outstanding good results, as it reduces the possibility of edge splintering without heat and vibration to cause damage to the carbon fibers.

Another set of parameters worth noting is the feed rate and cutting speed when using a cutting blade. These parameters affect the mechanical stress exerted on the material. Research shows that slower feed rates combined with moderate cutting speeds result in smoother edges which are less prone to jagged surfaces. Finally, avoiding the introduction of irregular cuts that weaken the material can be achieved by regular maintenance of the cutting tools – sharpening blades or replacing worn tooling. Following these precise techniques ensures an optimal outcome with material waste being controlled.

Are there any alternatives to cutting carbon fiber?

Exploring molding and shaping options for carbon fiber

Innovative approaches such as molding and shaping are starting to gain popularity as more efficient alternatives to cutting for carbon fiber, especially in precision disciplines with minimal waste of the material. One such method is compression molding. It consists of loading carbon fiber preforms into heated molds under very high pressure, which results in the consolidation of the material. May it be tight tolerances or moderate complexity, compression molding is very good at emplacing structures and the internal qualities of the compression molded parts tend to have high consistency due to the even pressure in the cavity. In addition, the development of resin transfer molding (RTM) techniques has allowed for accurate infusion of resin to carbon fiber preforms, providing stronger, but lightweight materials. Research suggests that RTM makes it possible to achieve an impressive resin content uniformity of 95% which significantly improves the mechanical performance of the final product.

An additional approach to consider is Autoclave Processing where carbon fiber composites are cured at high temperature and pressure environments. This technique is especially useful in the aerospace and automotive industries where performance and reliability are extremely crucial. Furthermore, advances in 3D printing such as Continuous Fiber Fabrication (CFF) are starting to gain popularity in the machinery for fabricating carbon fiber components. This method enhances the ability of manufacturers to place fibers within polymer matrices, bypassing the need to design and build components with low strength-to-weight ratios. Results from tests conducted on the components show that 3D printed carbon fiber parts have tensile strength exceeding 600 MPa which are suitable for high-performance engineering applications.

These methods of shaping and molding, if properly harnessed, can enhance the engineering properties of carbon fiber plates while reducing wastage and complexity of fabrication. In addition to this, these processes also satisfy the demand for efficient and environmentally sustainable manufacturing practices.

When to consider pre-cut carbon fiber parts

Pre-cut parts of carbon fiber offer great precision, efficiency, and consistency when the design and product has to meet a minimum requirement. These are economical because they do not require cutting, shaping, or finishing of the raw material. Instead, the materials are ready to assemble. These pre-shaped components are very popular in various industries such as marine, sporting equipment, automotive, and aerospace because they have great interchangeable uniformity and reduced wastage.

Pre-cut parts of carbon fiber come with a wide array of benefits such as improving production speeds and reducing costs. The pre-shaped parts are ready to apply which means a lot of labor-cutting processes are eliminated while also reducing lead times. This helps in the industry of automobiles especially when lightweight components need to be manufactured in precise schematics as there are stringent rules to be adhered to when it comes to meeting production timelines.

Pre-cut parts of carbon fiber are detailed, high in repeatability, and possess great accuracy. These components are especially useful for industries like aerospace where similar parts have to be made in bulk. Satellite data has shown that components that are pre-cut when consistently applied can help in maintaining tolerances to critical limits which are essential in ensuring the structural integrity and performance of the high-stress environments.

Design complexity is another important factor too. When projects involve complex forms or shapes, manufacturers save on material preparation by using pre-cut carbon fiber parts and focusing on assembly instead. For example, a lot of custom bicycle frame builders use pre-cut tubing to make frames that are lightweight and very stiff.

Finally, the use of pre-cut carbon fiber may reduce waste which helps to control expenses and protect the environment. Placing such a premium on carbon fiber makes it sensible to use pre-cut parts because each sheet or roll of carbon fiber will be put to its best use which is consistent with sustainable manufacturing practices. Research shows that the use of pre-cut parts compared to conventional bulk cutting methods can cut material waste by as much as 30 percent.

The incorporation of pre-cut carbon fiber in the production processes allows manufacturers to achieve greater benefits in efficiency, accuracy, and costs, thus offering broader use in different industries.

Advantages of working with carbon fiber fabric instead of sheets

Forming Flexibility

Compared with sheets, carbon fiber fabric provides more flexibility by enabling it to withstand intricate shapes and contours. This feature makes it suitable for work that requires complex geometry such as missile nose tip shapes.

Greater Detail in Design 

The construction of the fabric allows for accurate stacking and orientation of fibers to be done, which increases the strength and performance for particular load-bearing particulars.

Less Susceptibility to Brittle Failure

During the construction, fabric cracks less than rigid sheets, hence, ensuring better performance over time and repeatable results.

Simplicity in Process

Carbon fiber fabric is much lighter in weight which enhances its workability such cutting, layering, and resin impregnation, making these tasks considerably easier.

Finances Friendly for Little Work

Fabrics in lesser quantity can be utilized which reduces material cost significantly for work that needs extensive detailing.

Frequently Asked Questions (FAQs)

Q: What is the best and safest way to cut carbon fiber?

A: There is no universally ideal approach as the safest way to cut carbon fiber depends on the application’s scope. Nevertheless, the commonly recommended equipment includes a sharp coping saw, razor blade, or rotary tool with a cutter disk. Furthermore, to guard against inhaling the dust that will be generated, a mask and other protective clothing like goggles should be put on.

Q: Can I use a laser cutter to cut carbon fiber?

A: Sure! Laser cutters are a great tool for carbon fiber. They offer intricate designs and precise, clean cuts that are suitable for any project. On the downside, laser cutting does have its drawbacks. It burns resin and creates dangerous fumes, so appropriate ventilation is vital. The area around the cut also appears burnt, which may need some fixing afterward.

Q: What tools can I use to cut carbon fiber sheets?

A: You can use a broad array of tools including jigsaws with fine teeth blades, hacksaws, angle grinders fitted with abrasive disks, or even rotary tools with reinforced cutting wheels. If you would like to be more precise, you can use a CNC machine or a water jet cutter.

Q: Should someone use PPE while cutting through carbon fiber?

A: Yes. While cutting carbon fibre, you’re lungs will be exposed to fine dust and epoxy particles, therefore, it’s best to use a respirator or mask. To protect your eyes, as well as your skin, you will want to put on safety gloves. Most importantly, a helmet should always be worn and the workspace needs adequate ventilation.

Q: What is the most efficient method of cutting carbon fiber along straight edges?

A: A tidy cutting job on carbon fiber straight lines is best done with a guided circular saw along with a carbide blade. Thinner sheets are easier to cut as you can use a utility knife instead, just add a straightedge guide along it. It is best to score the cut line before applying pressure to get the desired piece.

Q: What is the best way to ensure a proper cut in carbon fiber construction?

A: For clean cuts, it is recommended to use high-quality blades which make the task easier. For carving, Always make the cuts outside the demarcated cuts on the slab and then sand the peripheries. To avoid fiber raveling, use high-speed tools over 10000 RPM. Using masking tape can also significantly remove the splintering which results in a cleaner cut along the demarcated line.

Q: What processes should be employed when molding carbon fiber composites?

A: While working with carbon fiber composites always ensure proper tools designed for composite materials are used otherwise they may break. Make sure the area is well-ventilated. During fabrication, cutting and sanding should always be done parallel to the grain. Always remember that cutting tools are prone to wearing off, thus blades need to be replaced more often.

Q: Are ordinary metallic machining apparatuses appropriate for cutting carbon fiber?

A: Although certain metal cutting tools are compatible with carbon fibers, their effectiveness is critical. Regular metal cutting tools are most likely to wear out quickly and become useless or damaged in the process. It is advisable to utilize systems intended to make composites or rough grinding wheels that can endure the hardness of epoxy resins and carbon fibers.

Reference Sources

1. (Paul Dudeja, 2018, pp. 519-527-519-527) This research paper centers on the application of fiber lasers in the cutting of carbon fiber-reinforced polymer (CFRP) composites. Noticeably:

• With traditional non-laser processes, the cutting of CFRPs is cumbersome and tedious. The utilization of continuous wave or pulsed fiber lasers will deal with many of these shortcomings.
• Power, pulse duration, and feeding speed have been optimized to minimize heat-affected zones during the cutting of CFRP.
• The ecological and safety aspects of composite CFRP structures cutting using lasers are also addressed.

2. (Hennigs et al., 2018) The development of a mobile laser cutting device suitable for rescue missions in which CFRP materials are involved is presented in this document. The central premises are as follows:

• The traditional rescue tool design became inadequate due to the prevalent use of high-strength steel and Carbon Fiber Reinforced Polymer (CFRP) materials in vehicle construction.
• The flexible laser cutting system aimed for will allow for the effective management of high-strength materials and multi-layer structures in thermal rescue applications.
• Laser cutting is a non-contact, wear-free processing method that provides major advantages; however, a significant drawback is the thermal damage that can often occur. Femtosecond pulsed lasers can be used to reduce the heat-affected zone.
• Experiments have shown that with optimized parameters, it is possible to restrict the width of the heat-affected zone to 25 μm.

3. (Qin et al., 2022, pp. 6361–6370)This paper is concerned with the gas-assisted laser cutting of CFRP. The key deductions are:

• The analysis focused on cutting experiments designed to profit from laser parameters (power, cutting speed, and assist gas pressure) with particular regard to kerf width, kerf taper, and the heat-affected zone.
• Using stronger laser settings widened the kerf and heat-affected zone, whereas cutting at higher speeds minimized those features.
• Comparative examination of the cut quality between gas-assist cutting with nitrogen or air and without gas showed that the former reduced kerf taper and heat-affected zone.
• The most effective settings were determined as: laser power: 1.2 kW, cutting speed: 1.2 m/min, assist gas pressure: 0.5 MPa.

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