I'm making 10 flat plates (approx 3.5" x 6.5") with a curved outline out of 0.063" thick aluminum sheet. This plate fits inside another assembly and I need to hold a tolerance of +/- 0.010". For my prototype I cut out the plate with a 1/8" flat endmill in 3 passes of 0.021" on my Taig CNC mill. If my production rate increases I will look into sending the work out for water jet, but in the meantime I'll be using the Taig mill (if you don't know the Taig mill, it's a small hobby mill with not much HP).
I'm wondering if a faster cutter is available - perhaps a roto-zip cutter? I'd like to cut the plates in one pass if possible (don't know if the Taig motor can handle that). I'd be OK doing minor clean- up of the edges with emery cloth if it cuts fast.
Any ideas?
Regards, Ed Ferguson