Cutting Tools for Aircraft Composites

If your project includes composite materials, which most do, you will benefit from some special cutting tools. Fiberglass is relatively easy to cut and trim. Tougher composites can be cut using the same tools but you will need extra blades, cutters and wheels. I have found that the easiest method to cut composite materials is using a grinder type air saw with a 2” saw blade. The high speed saw cuts through most composites very fast. Other options include a fine tooth jig saw or band saw, however this method may delaminate the edge of the material being cut. Another good method is to route the cut. You may do this using a high-speed router, preferably an air router, and a router guide. For materials other than fiberglass it is a good idea to check with the material manufacturer to see what cutter and cutter speed will work the best for that material. In most cases you can sand the edges with fine wet/dry sand paper to smooth and finish the cut.