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.