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This was a project i did for Mothers day, and also submitted for the C3D community challenge #9.
First attempt was in MDF, I thought maybe I could seal it up well enough but after talking with many people on forums, I wanted to make sure this would not be hurt by weather, so I went to Home Depot and picked up a sheet of 3/4" PVC. I gotta say, this stuff cuts like butter and I love it.
Tool 1 was a 1/4 2 Flute Carbide end mill (standard upcut). 150IPM feed rate 50IPM Plunge rate, .125 depth of cut, .1875 stepover.
Tool 2 was a 1/8 2 Flute Carbide end mill (standard upcut). 200IPM feed rate 50IPM Plunge rate, ."125 depth of cut, .09375 stepover.
Tool 3 was a 30 degree engraving bit 100IPM feed rate 50IPM Plunge rate, .".0625 depth of cut, cut on the profile of the chairs to get the fine details.
Tool 4 was a 1/4" Carbide Ball End Mill 400IPM feed rate 100IPM Plunge rate, .25" MAX depth of cut, texture tool path.
Tool 5 was a 60 degree Vcarve bit 200IPM feed rate 50IPM Plunge rate, .".0625 depth of cut, cut on the profile of the flip flop insides to get the fine details.
Tool 6 was a 1/4 Compression bit (only because it was the tool i have with 1" cut length) 100IPM feed rate 30IPM Plunge rate, .".125 depth of cut per pass, .77" total depth cut on the profile outside to cut free.
Once cut free, I hit the outside with the router table to give it some more rounded look.
After cutting, I Spray painted with a plastic primer spray paint (Krylon Fusion) and hand painted the rest.
This was all pretty quick thanks to my Bit Setter