Actually Lexan will machine quite well, it is just a matter of finding the correct speeds and feeds for your cutters.
My previous tests on my wood router were no good as my machine will only feed at 20 ipm max before it starts to
skip steps (really tight machine). My min router speed is 8000, which may be ok if the feed was high enough, but now
I can do it on the mill........
Here is a link to a site that shows one good method of testing for correct feeds and speeds in various materials:
http://precisebits.com/tutorials/calibr ... speeds.htm
It give a good explanation on the subject. I have yet to do the testing, although perhaps this week, as I now have
my cnc milling machine conversion completed, painted, finished.........just have to work out the 4th axis adapter to
attach a stepper to my rotary table, then we are totally done.
Next project design and build a proper cnc wood router, something that will be rigid and give me feed rates up to about
250 ipm at least.