PCD and solid carbide tools for composites

PCD & VHM Router Bits for Composites, Aluminum, and Plastics – Advanced CNC Machining

Processing composite materials, light metals, and technical plastics places completely different demands on cutting tools than conventional furniture manufacturing. To eliminate the risk of edge melting, layer delamination, or rapid edge dulling, ITA TOOLS has created a dedicated range of diamond (PCD) and solid carbide (VHM) router bits for composites. This high-tech tooling is engineered to manage complex waste and maintain total dimensional consistency in demanding processes.

Application and Material Compatibility

The construction and cutting angles of the tools in this group have been developed for precision cutting, slotting, folding, and sizing in advanced industrial materials:

• Sandwich & architectural composites: Alucobond, Reynobond, and Dibond type panels (including V-grooving bits for 90° and 135° bends).
• Fibrous composites: glass-reinforced plastics (GRP) and carbon fiber reinforced polymers (CFRP).
• Hard & mineral laminates: high-pressure HPL boards, Corian®, phenolic materials, and fiber-cement boards.
• Soft metals & plastics: aluminum, PVC window profiles, acrylic (plexiglass), technical foams, and polycarbonates.

Overview of Specific Geometries

• VHM multiedge rasp/router bits: Equipped with a dense, alternating cross-cut edge structure. They are insubstitutable in the machining of glass and carbon fiber composites. They act like a file – instead of pulling long fibers, they shred the waste into fine dust, eliminating edge fraying and delamination.
• Single-flute router bits (Z=1) for aluminum and plastics: These feature a single ultra-sharp, smooth, spiral cutting edge and a deep, polished chip evacuation flute. This design ensures immediate chip ejection, preventing the tool from clogging and stopping acrylic or PVC edges from melting.
• Profile PCD diamond router bits: Tools for chamfering, edge rounding, or making folding grooves (V-grooving) in composite panels. Brazed diamond tips on heavy, vibration-damping bodies (e.g., Densimet®) guarantee an industrial tool life.

💡 Find the tool right for your production: Use filters to instantly narrow down the product view. Select the application of the bit (for aluminum / for composites / for HPL), the cutting diameter, and the type of construction (rasp / spiral / profile) to perfectly adapt the parameters of the tool to the planned machining.

Frequently Asked Questions – FAQ

1. What is composite delaminating and how can it be prevented?

Delamination is a highly critical phenomenon where the sequential layers of a composite separate (e.g., glass mat peeling away from resin or aluminum debonding from the core in Dibond panels) under the influence of cutting forces. To prevent it, tools with a special geometry must be used. The VHM multiedge rasp bits from ITA TOOLS do not exert an axial force that pulls the material up or down – instead, they gently grind the edge structure, guaranteeing total cohesion of the composite.

2. Why should single-flute bits (Z=1) be used for plexiglass and PVC instead of multiedge bits?

Technical plastics like acrylic (plexiglass) or PVC have a low melting point. A conventional multiedge router bit generates too much friction, causing chips to melt and re-weld behind the tool, destroying the edge. Single-flute bits (Z=1) in positive execution feature a high-capacity polished spiral channel that immediately ejects a large, thick chip, effectively dissipating heat from the cutting zone and leaving the edge perfectly transparent or smooth.

3. When is it better to opt for solid carbide (VHM) or diamond (PCD) when working with composites?

• Choose solid carbide (VHM): For machining aluminum, flexible technical plastics, and in projects requiring very small bit diameters (e.g., 2-4 mm). VHM offers higher elasticity and resistance to breakage when working with ductile materials.
• Choose diamond (PCD): For highly abrasive materials that quickly dull carbide, such as HPL boards, fiberglass, carbon fiber, or fiber-cement panels. On these components, PCD diamond on Densimet® bodies maintains micro-sharpness for a long period, ensuring the lowest cost per linear meter of cut.

4. What router bits are used for composite panel folding technology (V-Grooving)?

To prepare panels like Dibond or Alucobond for subsequent manual bending, special VHM or PCD profile bits with cutting angles of 90° or 135° are used. These tools are designed to mill a precise V-shaped groove, removing the back layer of aluminum and the internal polyethylene core, leaving only the front decorative aluminum layer intact. This guarantees a perfect, straight bending line on facades without cracks in the material.