Any tips for deep slots/profiling in aluminium?

[m_c]

I've already ran the various figures through FSWizard, and know that spindle speed is the limiting factor, so I'm really looking for coping strategies.
I'll try single slotting it first, then if that's going to cause issues, I'll try and figure out some way to do a wider/double pass slot to create swarf clearance/make clearing swarf out easier, however that might involve lots of code fiddling in CamBam :/

My last attempt at cutting something out of 8mm plate resulted in the 4mm cutter getting destroyed at about 6mm depth.

This is a kind of exploration for a possible new product, so I'm looking to make it as pain free as possible on my existing little mill, and depending on success/failure will decide on my next machine.

[corkcnc]

Full depth trocoidal milling is probably best with a 3mm ripper, drill for the entry and stepping over .3mm on the passes. Then finish the last .1 with a single pass.
I'd use a 3mm ripper from WNT (I have no financial interest in the company), the 2 flute 50 960 030 would give you plenty of chip evacuation whilst still keeping up a decent feed and has about 12mm of cutting lenght.
I don't know your spindle limitations so I can't call the speeds and feeds. Just watch the corners, obviously one wrong move and snap but if you have a cad/cam system and if it is for a possible new product you can prove it with a 1mm DOC. A bit of planning would save you lots of time down the line.
Best of luck with it.
Noel.