D8961 solid end mill: Built for composite machining
Carbon fiber reinforced polymer (CFRP) is difficult to machine but we have a secret that can help. Find out what D8961 can do for you.Carbon fiber reinforced polymer (CFRP) is one of the most advanced materials used in industries like aerospace. It’s incredibly strong, lightweight, and durable but it’s also notoriously difficult to machine. The fibers are abrasive and the risk of delamination or poor surface quality is high.
Designed specifically to tackle the challenges of machining carbon fiber composites and thermoplastics, the D8961 combines a specialized patented geometry, advanced coating technology, and 5-axis capability to deliver consistent, high-quality results.
What is carbon fiber made out of?
Carbon fiber is made from long, thin strands of material composed mostly of carbon atoms. These atoms are bonded together in microscopic crystals, which align along the fiber to give it exceptional strength. A single carbon fiber is about one-tenth the diameter of a human hair, yet it’s incredibly strong and stiff. When combined with resins to form composites like CFRP, the result is a material that’s lightweight, corrosion-resistant and very tough to machine.
High productivity through specialized geometry
Looking to boost your machining performance? Thanks to its patented push/pull geometry, the D8961 solid end mill delivers stable cutting conditions, reduced vibrations and improved surface quality. Whether you're slot milling, drilling, or tackling complex 5-axis contouring, this tool handles it all. That means fewer tool changes, shorter cycle times, and consistently high-quality results when working with carbon fiber reinforced polymer (CFRP), thermoplastics, and other carbon fiber composites.
Your Challenge: Machining CFRP and carbon fiber composites often leads to delamination, fiber pull-out, and inconsistent surface finishes, especially when switching between multiple tools.
Our Solution: The unique geometry of the D8961 ensures stable cutting conditions across diverse applications, minimizing material damage and maximizing productivity.
Specialized in-house coating process increases tool life
Achieve 30-50% better tool life compared to the existing product line thanks to a grade development designed for improved bonding with the DURA diamond coating. Developed entirely in-house in Reynoldsville, USA, this coating is a game changer for extending tool life.
Your Challenge: CFRP is highly abrasive, leading to rapid tool wear and frequent replacements.
Our Solution: Our advanced coating technology ensures durability and cost-efficiency, even when machining thermoplastics and thermoset composites.
Tailored for complex CFRP components
When you're machining complex CFRP aerospace components you need a tool that can keep up and obey tight tolerances. D8961 is 5-axis capable, which means it can handle intricate geometries in a single setup. And if your job calls for something more specific, we offer custom tooling options like extended cut lengths and specialized geometries to match your exact needs, so you can adapt to unique fixture constraints and material thicknesses.
Your Challenge: Complex CFRP components often require multiple setups and custom tools, which can lead to misalignment, tool wear, and inefficiencies.
Our Solution: With D8961, you get precision and flexibility in one tool. Its custom options and 5-axis compatibility help spread wear evenly and keep cutting edges cool so you get reliable results, every time.
Reduced carbon footprint
D8961 isn’t just about performance, it’s also about responsibility. By developing and applying our diamond coating entirely in-house, we cut out unnecessary shipping and reduce our environmental impact. That means fewer emissions, faster turnaround times, and less waste. It’s a smarter, more sustainable way to manufacture high-performance tools.
Your Challenge: As sustainability targets become increasingly critical across industries, manufacturers are under pressure to reduce emissions, streamline supply chains, and choose environmentally responsible partners.
Our Solution: With in-house coating and geometry development, we control the entire production process which reduces emissions, improves efficiency, and aligns with your sustainability goals.
Technical specifications
| Geometry | D8961 |
| Type | Router |
| Range | 5mm – 16mm (.0250” – 0.625”) |
| Number of flutes | 6RH |
| Grade | DURA |
| Cutting length variants | 2, 3 |
| No of items | 14 Metric (10 Imperial) |
| Application | Shoulder and slot milling |
| Material | CFRP (Carbon Fiber Reinforced Polymer) |
Working areas
The design of the D8961 Router gives you an extremely flexible approach to machining composite materials. With its advanced geometries and coating, it delivers exceptional results in abrasive materials and is engineered for high-performance machining across a wide range of demanding applications.
• Slot Milling
• Shoulder Milling
• Ramping
• Helical Ramping
• Drilling
• Plunge Milling
• 5 axis contour milling
