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Still searching for a solution for these letters. I did the final passes on them with the tapered end mill I posted about and I'm just not happy with it. I knew it would trim away the more of the material at the top edges but its more than I would like and it kind of obliterated the hole in the R. L and arrows look great but the R is a bust.
So Im wondering if you can mill aluminum with jeweler's burs if I take very light cuts. Would get one of the AB holders with them. They are made with vanadium steel, not sure if that is just a fancy marketing name or what but I assume it's just high-speed steel. ? The thing I like about the possibly is I have tons of them from my machining days back in the toy industry and they are all lollypop cutters, so I can capture more of the undercuts on the top edges of the letter which will give me a much better cavity for the letter. Do you think they will work?
Fusion