Acrylic is hard to cut! I’ve mainly been working on clear acrylic.
So far, I’ve had the best results using the straight 2 flute bit (the one sold here on Inventables and included in my End Mill Starter set) at a feed rate of 40in/min, 0.02" deep passes.
This works great up until about 3/16" deep, when there begins to be a lot of material against the bit that isn’t being cut…just rubbing and generating heat. Then things start to get a bit melty. Small gobs of molten acrylic travel up the bit, fouling the nicely cut surfaces in the upper layers, before being flung across the room in every direction.
Any tips to get good cuts in 1/4" acrylic? I don’t know if I should be focusing on the bit, feed rate, depth, or technique.