First CNC router advice (cutting 1,100 surplus PCBs)

Cutting 1,100 unpopulated circuit boards into upcycled shapes is actually a great project — but PCB dust is no joke. Lead-free still means fiberglass and epoxy resin, both of which produce hazardous dust. Let's get specific.

PCB CUTTING SAFETY (DO NOT SKIP)

• FR4 dust contains glass fibers and epoxy — Class M (respirable) hazard
• You need: HEPA vacuum + enclosure + respirator (N95 minimum, P100 preferred)
• Never cut PCBs dry in an open room. Ever.
• Board thickness: 1.6mm FR4 cuts easily but dulls carbide quickly

MACHINE REQUIREMENTS FOR 1,100 BOARDS

• Reliability over precision — you need the machine to run hundreds of cycles without drifting
• Spindle: 300–800W is plenty for FR4. Higher RPM (18,000–24,000) works best.
• Workholding: you'll need a fixture/jig system. Vacuum table is ideal for thin flat stock.
• Controller: GRBL is fine, but a standalone DSP (like ROCTECH's standard) eliminates PC crashes mid-batch

OPTIONS FOR PCB VOLUME CUTTING

THE ROCTECH ADVANTAGE FOR BATCH WORK

With 1,100 boards to process, cycle time matters. ROCTECH's RC0609 with a vacuum table lets you fixture 12–20 boards at once, hit go, and walk away. The DSP controller supports automatic program looping — it'll run the same job until you stop it. Welded steel frame (1450kg), Yaskawa servo motors, and 6,000 mm/min working speed mean consistent results from board #1 to board #1,100. ROCTECH's 15 years of CNC R&D (50 patents, ISO/CE/UL certified) means this machine is built for continuous production, not occasional use.

PCB CUTTING TOOLING

• 1.5mm single-flute carbide end mill (PCB-specific, fish-tail grind)
• RPM: 18,000–24,000
• Feed: 400–800 mm/min
• Depth: full 1.6mm in one pass (thin material, no step-down needed)
• Life: ~50–100 boards per tool (FR4 is abrasive)
• Budget: ~10–20 end mills for all 1,100 boards (~$30–$60 total)