The cutting method for FR4 fiberglass boards needs to be selected based on the board thickness, precision requirements, and production dimensions. It's crucial to ensure a smooth surface and dimensional accuracy while avoiding cracking or fiber exposure due to improper handling. Below are common cutting methods and key operational points:

1.Manual Cutting (Suitable for thin sheets and small batch processing)

Utility Knife Slicing Method: Suitable for thin sheets with a thickness ≤3mm. To operate, first fix a ruler along the cutting line. Use a utility knife (industrial-grade high-hardness blade recommended) to repeatedly score along the ruler until the depth reaches 1/3-1/2 of the sheet thickness. Then, place the sheet along the scored lines on the edge of a table and press down firmly with both hands to break it.

Hand saw cutting method: Suitable for boards with a thickness of 3-10mm. Use a fine-toothed hacksaw (≥18 teeth/inch). When cutting, keep the saw blade perpendicular to the board and advance slowly and evenly to avoid excessive force that could cause the board to crack. After cutting, use a file to smooth the cut to prevent fiberglass from pricking your hands.

2. Mechanical Cutting (Suitable for medium and heavy plates and batch processing)

Electric Saw/Circular Saw Cutting Suitable for plates with a thickness of 5-50mm, with high efficiency. Requires a diamond saw blade or a carbide saw blade (the number of teeth depends on the thickness; use a fewer-tooth blade for thicker plates and a more-tooth blade for thinner plates). Adjust the saw blade speed during cutting (usually 3000-5000 rpm). The plate must be secured with clamps to prevent vibration from causing a skewed cut. Simultaneously, use water or compressed air to cool the saw blade and the cut to prevent the resin from scorching due to high temperatures.

Milling/Engraving machine cutting is suitable for scenarios requiring high-precision cutting of irregular shapes (such as complex contours and openings). By installing a milling cutter (made of carbide or diamond), milling is performed along a preset path with an accuracy of ±0.1mm. During operation, the feed rate must be controlled (typically 50-200mm/min); excessive feed rate can easily lead to delamination of the sheet metal or tool wear.

3. High-Precision Cutting (Suitable for Precision Parts Machining)

Laser Cutting is suitable for sheet materials with a thickness ≤10mm and requiring a smooth cut. It utilizes a high-power laser beam (CO₂ laser or fiber laser) to melt and evaporate the material, achieving non-contact cutting with burr-free cuts, high precision (±0.05mm), and no mechanical stress that could cause sheet material deformation. However, laser cutting can cause slight carbonization of the resin at the cut, requiring post-processing (such as grinding) in applications with strict insulation requirements.

Waterjet cutting is suitable for various thicknesses (especially plates thicker than 20mm) and heat-sensitive applications. It uses a high-pressure water jet (mixed with abrasives such as garnet) to erode and cut, eliminating the heat-affected zone and producing a clean, smooth cut. It can cut complex shapes. However, the equipment is relatively expensive and is best suited for mass production and precision machining.

Cutting Precautions

Safety Protection: Fiberglass dust and debris will be generated during cutting. Wear a dust mask, goggles, and gloves to avoid inhalation or skin contact (fiberglass may cause itching).

Avoid Overheating: Insufficient heat dissipation during mechanical cutting can cause the resin to soften and stick to the blade, affecting the cut quality. Prompt cooling is necessary.

Secure Fixation: Regardless of the cutting method, the sheet material must be securely fixed to the worktable to prevent slippage that could lead to dimensional deviations or accidents.

Post-Cutting Processing: After cutting, use sandpaper, a file, or a dedicated deburring tool to treat the cut edges, removing sharp edges and exposed fibers to ensure safe use.