Quote Originally Posted by Jonathan View Post
The issue with a bandsaw and difficult to cut materials is new blades will cost about £6-£8 and may not last longer than much cheaper blades for fret saws.

I didn't have problems when cutting 5mm thick copper on my CNC router, but maybe I just got lucky.

Roughly many of these broaches is your wife making? If they're all different shapes then a fly-press wont be cost effective, but getting them laser/plasma cut might be? If you do cut them on a router you're in danger of making her redundant as the router can of course do all the engraving...
What was the power and speed of the router motor when you cut the 5mm ?
Was it on a CNC machine ?
Thanks