Level A – Industrial & High-Volume Shops
When to Use Level A:
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You're processing over 100 linear feet of acrylic daily.
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Your equipment includes professional features like mist-coolant or dedicated air-blast systems.
Equipment Recommendations:
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3 kW water-cooled spindle
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Premium coated O-flute bits (such as Amana Tool or Onsrud)
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Closed-loop feed-rate control for optimal performance
Ideal Feeds & Speeds:
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Chip-load: approximately 0.007 inches
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RPM: 24,000; Feed: 160 IPM
Results to Expect:
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Crystal-clear edges straight off the machine, minimal to no post-processing required.
Level B – Best Budget Workflow for Hobby CNCs (Most Readers Fit Here)
When to Use Level B:
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Hobbyists or small shops processing under 40 linear feet per day.
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Primarily creating signs, decorative panels, or custom acrylic projects.
Recommended Equipment:
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Trim router or entry-level 1.5 kW ER-11 VFD spindle
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Affordable ¼-inch or ⅛-inch O-flute router bits, either uncoated or TiB₂-coated
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Simple chip evacuation system using a shop vacuum or basic air-blast (~30 PSI)
Ideal Feeds & Speeds:
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Chip-load: approximately 0.005 inches
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RPM: 18,000; Feed: 95 IPM
Results to Expect:
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Good edge clarity with minimal haze; easily improved through flame polishing or sanding.
Recommended Budget-Friendly Bits:
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SpeTool Single-Flute Bits: Affordable and reliable performance.
Quick-Start Implementation Checklist for Level B
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Select a Bit: Choose a reliable single-flute bit priced between $15–$25.
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Initial Settings: Start with an RPM of 18,000 and a feed rate of 95 IPM for a ¼-inch bit.
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Effective Chip Evacuation: Use a vacuum shoe or side-mounted air blast.
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Test Cut: Adjust incrementally until edges are clear and free from melting.
For additional insights, read our comprehensive guide on Up-Cut vs Down-Cut Router Bits.
