I have a couple of jobs i make in small batches, they all have features that must have the ability to accept a square part - the way this is done with a round cutter is by dog-boning or T-boning the corners, this gives a result like the picture here...

Click image for larger version.  Name: Vectric Bed Plate [Converted].jpg  Views: 182  Size: 16.3 KB  ID: 20825

The materials are either 3mm or 5mm thick and the tool is 2mm chosen as the smallest sensible size for the job.

So, being a small tool, it only takes small cuts and to make the corners takes around 5 passes on the 3mm plate, this takes a fair bit of cycle time.

Is it better to plunge-cut the corners with the tool first and then run the straight edges at a larger DOC probably 2 passes??

Will a 2mm tool plunge through 5mm aluminium ?

Some of the features are far bigger and take even longer naturally.