mick40 wrote:Can you tell us what cutters you used? For MDF to hold the detail and not rip out your doing something the rest of us would like to know about. Beautiful!!!!
I used a 1/16" tapered 3 flute EM for the detail, and a 1/4" 3 flute EM for the rest. There were 3 layers (0.5mm, 1mm, 1.5mm), done with offset pocket toolpaths.
I find the trick is in the order things are cut. The fine details on the top gears were cut first, and I skipped the clearance EM, using the 1/16" only.
The rest of the top layer and the two following layers were cut with both EMs. However, I moved the 1/16" finishing passes to the top of the list, so they all cut first and then the clearance passes cut second. Aside from minimizing toolchanges, I believe this is what let me cut fine detail without tearing.
I also hate MDF, I wish I could afford to stock HDU for something like this. It was crazy watching how fuzzy the cut would get the further into the sheet it would go (how less dense the MDF is in the middle, even in 1/4" material).