This weekend I needed to cut some shapes out of 1/8" thick aluminum (climbing hooks for an FRC robot). I’ve worked aluminum successfully before (up to 1/4" thick), and used the same settings (1/8" bit, 10in/min feed, 3in/min plunge, 0.002in depth per pass). The X-Carve initially did a perfect job of cutting the nine 0.201" diameter holes (63 passes per hole), but when it started cutting the outline, it dropped to a (caliper measured) depth of 0.05in! Naturally, it did a crappy job cutting for about 4" before the bit broke. Unfortunately (or maybe fortunately?), I wasn’t there at that moment, or I would have stopped it immediately.
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