Composite Machining
CNC Machining of Glass-Filled Thermoset Composites
G7 Glass Silicone • G9 Glass Melamine • G10 / FR4 Glass Epoxy • G11 Glass Epoxy
Mayfly Manufacturing specializes in precision CNC machining of thermoset laminate composite materials for demanding engineering applications. We understand the unique challenges of machining laminated composites, and our processes are built specifically to address them.
Whether you’re prototyping or running production, we machine composite parts correctly the first time.
Why Composite Machining Requires a Specialist
Composites behave very differently than metals or plastics. Without the right approach, parts suffer from:
- Edge fraying and delamination
- Poor surface finish
- Fiber pull-out
- Dimensional instability
- Excessive scrap rates
- Dry machining strategies to reduce contamination on critical parts
At Mayfly Manufacturing, composite machining isn’t an afterthought—it’s a core capability.
Our Composite Machining Capabilities
We machine a wide range of thermosets and laminate grades, including:
- Epoxy-Based (G10, G11, FR4) – Strong mechanicals, good electricals, heat resistant. FR4 adds flame retardants to G10.
- Silicone-Based (G7) – Excellent heat resistance, elasticity, arc/flame resistance.
- Melamine-Based (G9) – High arc resistance, good mechanicals.
Typical Capabilities
- Tight-tolerance CNC milling and turning
- Precision drilling and profiling
- Fixture-based repeatability
- Prototype through low–medium volume production
- Secondary operations as required
Typical tolerances of ±.005” are common, with tighter tolerances possible depending on material and geometry.
If your application requires flatness, edge quality, or dimensional consistency, we’ll help you determine the right approach before cutting material.
What Sets Mayfly Manufacturing Apart
Composite-Specific Processes
We use specialized tooling, feeds/speeds, and toolpaths specifically developed for laminated composites—minimizing delamination and maximizing part quality.
Clean, Controlled Machining
Composite dust control and cleanliness are critical for both part quality and safety. Our shop practices are designed to handle composite materials responsibly.
Engineering-Focused Support
We regularly work directly with engineers to:
- Improve manufacturability
- Reduce cost
- Increase yield
- Prevent common composite failures
Reliable, Repeatable Results
Purchasing teams value us for:
- Consistent quality
- On-time delivery
- Clear communication
- Honest feedback on manufacturability
Common Applications for Composite Parts
Our customers use machined composite components in applications such as:
- Electrical insulation and housing components
- Structural spacers and plates
- Wear-resistant components
- Medical Equipment
- Aerospace and industrial fixtures
- Knife and Firearm Handles
- High-strength, non-conductive parts
If your part requires strength, stability, and electrical insulation, composites may be the right solution—and we can machine it accurately.
Design Tips for Machining Composites
Early design decisions have a major impact on part quality and cost. We’re happy to review prints, but here are a few general guidelines:
- Avoid sharp internal corners when possible
- Consider fiber orientation in critical features
- Specify tolerances only where functionally required
- Allow adequate stock for finishing passes
If you’re unsure, we’ll help you refine the design before production.
Request a Quote for Thermoset Composite Machining
Looking for a reliable CNC shop that understands composites?
Upload your prints or models, and one of our engineers will review your requirements and follow up promptly.
