I took a shot at making one of the Butterfly Puzzles in .063 aluminum this morning and it turned out beautifully. I used a .062" 2 flute with a bit of kero to lube the aluminum running at 8 IPM's with .022" depth cuts.
I think if I had to do it all over again, I'd do it without tabs as it needed a lot of clean up. My wife loves it in the rough brushed natural aluminum, but I'd like to see it anodized in a color.
I had to seperate the parts into 3 sheets of 4X8" as I did this on a Taig Mill. Took about 120 minutes to machine and about another half hour to clean up the edges and put a rough 220 grit finish on it.
I have the "bug" now to make more of these, but time is not something I have a lot of :roll:
Thanks,
Dave