G-Wizard?

[Tenson]

Thanks, I just tried some cutting again with the suggested feeds and speeds of G-Wizard and it doesn't melt the plastic as I thought it might. I guess the key is getting enough chip-load not to cause rubbing.

I'm cutting 8mm sheet, so I did multiple 3mm pass' at first with a 6mm cutter and then did a finishing pass at full depth removing 0.5mm of material. The end result is very good but there are still some very slight snipe marks. I need to sand and buff it afterwards for a real smooth finish. I tried flame polishing it with a butane pen torch but I think the flame is not hot enough as it looks a little patchy.

[Jonathan]

I guess the key is getting enough chip-load not to cause rubbing.

When cutting plastics and aluminium that is exactly what you need to to. With other materials, such as wood, you tend to get away with too small a chipload as it just wears the cutter faster, instead of immediately breaking it.

I'm cutting 8mm sheet, so I did multiple 3mm pass' at first with a 6mm cutter and then did a finishing pass at full depth removing 0.5mm of material.

When I need a good finish on something made from aluminium I cut the part 0.1mm or 0.2mm oversize, then do a finishing pass at full depth, so long as it's not thicker than 25mm which is rare. You could try leaving less than 0.5mm as the lower force on the tool may make a difference, however the chipload may be too small unless the feedrate is increased...