Chip and dust removal during the trimming of carbon-fibre reinforced polymer (CFRP) parts is still an important challenge to overcome by the manufacturing industry to protect operators from the health hazards associated to CFRP dust and chips. Therefore, novel PCD cutting tools and a special spindle with internal suction capability have been designed and developed, providing an effective fibre and dust removal from the working area during robotic trimming. Nevertheless, in order to guarantee a totally clean machining process, cutting conditions need to be carefully chosen. Indeed, not only conventional process aspects such as part surface quality, tool wear and productivity must be considered, but also the effectiveness of the chip and dust suction must be studied. Thereby, experimental work for process optimization has been carried out, analysing the effect of different process conditions on suction rate and surface integrity. Finally, optimum cutting conditions are identified for the concerning set-up obtaining a nearly 100% aspiration rate resulting in a safe CFRP machining process. This research has been made in the framework of COMACH project of SMART Eureka cluster program representing a close cooperation between Turkish and Spanish companies and research organisations.