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Tony, I'm curious what the reccomendation for 3XXX series aluminum would be. My experience was that you needed a rather aggresive chipload (3 to 5 thou is a starting point), sharp (as in brand new) single flute cutters, a micromister with lubricant and a very aggressive feed rate (as well as a...
Is there any reason why you don't use a NuArc with an integrator, they sell pretty inexpensively, mine cost me nothing, in fact. (though I use mine for photographic pursuits, not burning screens, though I have in the past)
been a while since I've run a router, but I tend to prefer more rather than less coolant. 5XXX aluminums can be easily cut with a single O flute bit with .001" to .002" chipload, with proper cooling and lubricant. (not just coolant) chipload is critical, as the chips carry the heat away, too...
Usually, one uses dye sub to print on fiber reinforced polyester blanks, aluminum would need to be sub coated to even accept the dyes. Dye sub is common for vandal proof signage, but not on aluminum.
erie
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