Category: CNC Routing

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CNC Routing – Aluminum Composite Material (ACM)

CNC-Routing-ACM-Material

Aluminum composite material is often cut out on a CNC router. The versatility of this material is what makes it so popular. From outdoor signage and constructing walls to channel letter backing, the possibilities are endless. Compared to single-layer aluminum plate, ACM is lighter and more affordable while still offering durability and rigidity. For those looking to learn how to cut this material, follow along.

For this experiment, we set out to create the backing of a box for a sign. This entailed cutting out the shape of the box, v-grooving the sections that needed to be bent to shape, and drilling holes for attaching the face of the sign.

Cutting Through

We cut through 3mm ACM with an X-Edge 1/4″ single o flute upcut bit (XVO2232). This bit does very well on both aluminum and ACM. We found that cutting in climb direction produced the best finish. Our feed rate was 200 inches per minute (IPM) and our spindle speed was 22,000 rotations per minute (RPM). This seemed to do very well, cutting through the entire material in one pass.

XVO2232 (1/4″ Single Flute Up-Spiral)

V-Grooving To Bend

Some important factors for v-grooving ACM to bend are controlling the cut depth and using the correct tool. The v-groove tool should cut through the first layer of aluminum and the center plastic layer. The goal is to get as close the the second layer of aluminum as possible without cutting through any of it. This allows it to bend while still being durable. Using a tool with a flat tip is very important. When you eventually bend the material, it needs space to ben properly. A bit that comes to a full point does not leave enough room for this. That is why we used an X-Edge 2 flute 90 degree bit with a flat tip (XACM90-V). Our feed rate was 150 inches per minute (IPM) and our spindle speed was 14,000 rotations per minute (RPM). This again seemed to do very well, cutting through both layers in one pass.

XACM90-V (Two Flute 90 degree V)

Drilling Holes

If you need to drill multiple holes, I highly recommend using a 2 flute carbide drill bit. These are created for long life and making perfect drill holes on a CNC machine. For this experiment, we needed 1/4″ holes so we used a 1/4″ 2 flute solid carbide drill from X-Edge. Our plunge rate was 100 inches per minute (IPM) and our spindle speed was 4,000 rotations per minute (RPM). This cut through all three layers, smoothly and accurately.

XCD2082-S (Two Flute Solid Carbide Drill)

Quick Details / Recommendations:

  • Material: 3mm aluminum composite material (ACM)
  • Tool # 1 (cut through) single o flute upcut (XVO2232) – BUY HERE
  • Feed Rate: 200 IPM / Spindle Speed: 22,000 RPM / 1 Pass
  • Tool # 2 (to bend) 2 flute 90 degree v-groove w/ flat tip (XACM90-V) – BUY HERE
    • Feed Rate: 150 IPM / Spindle Speed: 14,000 RPM / 1 Pass
  • Tool # 3 (1/4″ holes) 2 flute carbide 1/4″ drill bit (XCD2082-S) – BUY HERE
    • Plunge Rate: 100 IPM / Spindle Speed: 4,000 RPM

When orders are placed, they will be double checked to ensure no errors were made and customer follow up will take place during the same day (unless an order is made after hours). If products are available, which most of them are, they will be shipped out the same day. If they are not available, a lead time will be provided. Feel free to reach out for any assistance with our website or anything else regarding CNC routing and knife cutting.

CNC Tooling Shop, a division of Specialty Machinery Inc.

Email: tooling@cnctoolingshop.com

Hours: 8:00 AM to 5:00 PM (EST)

Phone: (616) 502-7277

Greg Smolka (Author)

CNC Tooling & Application Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and cutting recommendations (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com

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The CNC Wood Routing Handbook – A Beginners Guide

CNC Routing Wood - CNC Tooling Shop

CNC routing unlocks a world of wood cutting possibilities. Each species brings its own personality to the machine table: softwoods that carve like butter, hardwoods that fight back with stubborn grain, and engineered boards that demand a careful balance of speed, tooling, and technique. A successful project isn’t just about uploading a file and pressing go. It’s about understanding how maple chips under pressure, why birch loves a sharp bit, and what makes walnut smoke when feeds and speeds aren’t dialed in. Mastering those nuances turns a CNC router from a generic cutter into a precision instrument that respects the nature of every board it touches.

Router Bits

First off, let’s dive into some of the most common wood cutting bits:

  • Compression Bits: Made with both an upcut and downcut portion in order to minimize material fraying
  • Downcut Spirals: Great for profiles (when not cutting all the way through)
  • Upcut Spirals: Great when fraying is not an issue and chip removal is important
  • Bradpoint Drills: For creating partial holes for dowel pins
  • Through-Hole Drills: For drilling holes completely through wood
  • V-Grooves: For beveling edges or engraving designs

Feeds / Speeds

There could be an article written on the feeds/speeds for each type of wood, so I’ll provide some basics. Feel free to reach out to me for further information, recommendations, and tips/tricks.

Compression Bits are your most common tools for cutting wood. They are specifically designed to eliminate fraying, increase feed rates, and extend tool life. The 3/8″ Compression tool is the most common, so here are a few feeds/speeds by material that I would recommend (assuming that you are using an industrial CNC router) with a 3/8″ Compression. My most sold 3/8″ compression bits are XC2023 and mortise version XC2023-M. If you need a coated version (for longer tool life or laminated wood), then the 60-124MC is great.

MaterialFeed RateSpindle SpeedPer Pass
Solid Wood450-550 IPM18,000 RPM3/4″ or less
HPL / HDF500-600 IPM18,000 RPM3/4″ or less
MDF550-620 IPM18,000 RPM3/4″ or less
Plywood550-650 IPM18,000 RPM3/4″ or less
Melamine600-700 IPM18,000 RPM3/4″ or less

Now that you see the different feed rates that are needed for each wood material, I’m sure that you can imagine how much they will change as we get into upcuts, downcuts, drills, and v-grooves. Again, feel free to reach out if you’d like me to go through your entire project or operation. As long as you get tools through me, I’m happy to help.

One last note that I’d like to make on feeds and speeds is that drilling operations act very different. Drills, whether brad point or through-hole drills are plunging, not cutting side to side. Because of this, low RPM’s are VERY important. The same way you start a fire in the woods by spinning a stick in place, this can happen on your CNC router bed. I’ve seen it happen and helped CNC operators work through the mess of repairing their burned machine. Common feeds and speeds for drilling holes is often in the range of 4,000 – 8,000 RPM at a plunge rate of 100-200 IPM. Pecking motions in and out of the wood can also help remove chips and in turn heat buildup.

Left-Hand vs. Right-Hand Tooling

Left-hand versus right-hand tooling matters far more in CNC wood routing than most newcomers expect. Hardwood fibers behave like tiny stubborn soldiers, and the direction your bit spins determines whether you’re slicing them cleanly or going against the grain and in turn removing chunks of material. Right-hand tools dominate the industry, spinning clockwise to pair with the standard router motor rotation while evacuating chips efficiently upward or downward depending on flute geometry.

Left-handed tools sneak into hardwood routing for several smart, practical reasons, almost like the secret agents of the tool rack. Hardwood likes to fight back, and sometimes flipping the cutting forces is the only way to keep the peace. A standard right-hand bit may try to lift the work off the table or peel grain in the wrong direction, while a left-hand bit pushes the part down instead, keeping clamps and vacuum hold-downs happy. Some setups also need chips traveling the opposite direction for cleaner extraction, cooler cutting, and less scorching on wood that already resents heat. When machining both sides of a component or working in mirrored operations, left-hand tools keep edge quality consistent where the grain would otherwise splinter. They’re not common, though when hardwood starts misbehaving, a left-hand spiral suddenly becomes the hero.

Material Hold-down

Vacuum hold-down is crucial when CNC routing wood. It’s like giving your material an invisible bear hug so the router can hog out large amounts of material quickly. Vacuum tables spread suction across the entire sheet, perfect for large panels and nested projects. Vacuum cups, on the other hand, elevate smaller parts or projects needs side profiles (like doors), gripping specific areas with concentrated force so edges, profiles, and pockets stay crisp without tabs or tape. Hardwood can be slippery and determined to wander when cutting forces ramp up, so choosing between a full vacuum table and precision cups depends on part size, surface area, and how dramatic that wood plans to be during machining. A stable hold means cleaner cuts, safer routing, and no surprise airborne souvenirs. Here are a few materials that you can use as a sacrificial board “Spoilboard” on a vacuum table that will allow air to flow through and assist material hold-down.

  • Standard MDF (Mill both the top and bottom layer before using)
  • LDF (more porous equals more airflow)
  • Ultralight MDF (even more porous equals more airflow)

Mastering the art of CNC wood routing isn’t just about knowing your machine, it’s about understanding the character and behavior of every board that lands on the table. From selecting the right bit geometry to dialing in feeds and speeds that respect the density of each species, every choice influences the outcome. Vacuum hold-down keeps parts grounded, while the often-overlooked balance between left- and right-hand tooling ensures grain and chip flow stay on your side. Once these fundamentals click, your CNC router becomes less of a power tool and more of a creative partner, transforming raw wood into precise, polished work worthy of its natural origins.

15% OFF CNC Router Bits
Greg Smolka

Greg Smolka (Author)

CNC Tooling & Applications Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and applications (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com | (616) 502-7277 | LinkedIn

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Why are my CNC bits breaking?

Why Your CNC Bits Are Breaking

Every so often, I’m asked the question “Why are my CNC bits breaking?” and then the process of elimination begins. There are an array of issues that could be causing this to happen. Here are the most common:

  1. Incorrect feed/speed
  2. Dull bit
  3. Bad vacuum/hold-down
  4. Debris in collet/tool holder
  5. Bad collet

Incorrect Feed Rate & Spindle Speed

First off, the feed rate and spindle speed are often the culprit. Bits can break at too high or too low of both the feed rate and spindle speed. It’s important to find the correct mix of feeds/speeds that meets your material and quality requirements. The easiest solution for this is to send an email to tooling@cnctoolingshop.com. On a daily basis, I’m troubleshooting and offering starting points on how to cut a specific material for my customers.

Dull Bit

Most operators know this, but a dull CNC bit is far more likely to break than a new sharp one. Instead of the dull bit cutting through the material, the pressure is pushing through it until it no longer can. In this case, a smaller diameter tool will break before a larger one will. Pay attention to the cut quality and sound coming from the tool when a new tool is cutting vs. a used one. This way you can spot a dull tool before it breaks or sacrifices too much quality.

Poor Vacuum/Hold-Down

Bad material hold-down can very easily break a bit. Vibration or material movement is the enemy. The hold-down could be bad because of vacuum problems or even a vacuum not suitable for your machine, lack of milling the spoil board, vacuum pressure leaking out the side of material, etc. Do whatever you have to do to keep material held in place. Some people use double-sided tape, down-spiral bits, vacuum cups, or vacuum enhancers to further decrease movement. Again, do everything in your power to keep material held in place.

Debris In Collet/Tool Holder

If tool holders and collets are not properly cleaned, debris can build up and cause the tool holder to be off balance. When your CNC machine is cutting material out of balance, you face a decrease in tool life, spindle life, and cut quality. This can easily be a reason why your bits are breaking. Remember that collets and tools holders are consumables and should be replaced in a reasonable time-frame. See a recent article, I wrote, with more detail on tooling maintenance HERE.

Bad Collet

Like I mentioned above, collets are consumables. Depending on use, collets have a 90 day life. When you break a bit near the collet, they should also be replaced because they can damage the collet to where it no longer holds a bit correctly. Think of a collet as a spring. If a spring is compacted together for 90 straight days, it will no longer be the spring it once was. Therefore, your CNC bits are not being held as tight and balanced as they need to be. Find collets on our webstore HERE

Greg Smolka

Greg Smolka (Author)

CNC Tooling & Application Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and cutting recommendations (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com

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CNC Routing: EVA Foam (Marine Flooring)

CNC Routing: EVA Foam Marine Flooring

EVA Foam (Ethylene-Vinyl Acetate foam) is a soft, flexible, and durable material made from a blend of ethylene and vinyl acetate. It’s known for being lightweight, shock-absorbent, and resistant to water, UV radiation, and chemicals. It’s key characteristics include being lightweight and flexible, water resistant, shock-absorbing, and easily cut, shaped, or heat-formed.

Common Uses

  • Flooring: marine flooring, gym mats, play mats, and anti-fatigue mats
  • Crafts and cosplay: for making costumes, armor, and props
  • Footwear: midsoles of athletic shoes and sandals
  • Packaging: protective padding for fragile items
  • Sports gear: padding in helmets, guards, and yoga blocks

Today, we’re discussing EVA foam in marine flooring because I’ve been asked one too many times how to cut and shape it. We came up with a simple way to cut your created designs and logos in EVA foam as well as cut out the outer shape in order for pieces to fit in very specific places. This is very important when working on a flooring project for a customer.

EVA Foam Marine Flooring

EVA foam began gaining popularity for marine flooring in the early 2000s with companies like SeaDek pioneering and popularizing it, though it became much more mainstream around the 2010’s as manufacturers started marketing it specifically for boats and watercraft. Being a non-slip, cushioned, easy-to-install material that could stand up to the water and sun made it catch on quick. Today, EVA foam is a top choice for both recreational and professional marine use.

How to Cut

I’m guessing this is why you came here, so let’s get to it. We designed a (5) tool kit that allows anyone with a CNC router and marine flooring grade EVA foam sheets the capability to bring their designs to life. You’ll also need a razor blade or a CNC knife blade to cut out the outer shape of the pieces, but that blade will depend on the brand of your CNC router or knife cutter.

Step 1: Buy The Kit

You can view and purchase the 5-tool kit HERE.

Step 2: Choose the center line size

Our kit includes a 3/16″ and a 1/4″ 3 Flute router bit. These sizes seemed to be the most popular center line options. Other sizes are also available. Feel free to reach out if you’d like something additional. This tool needs to be ran in both climb and conventional directions in order to achieve best quality. We found that a spindle speed of 22,000 RPM and a feed rate of 100-150 IPM worked perfectly.

Step 3: Choose a Ball Burr size

The ball burr router bits are the tools that really bring the designs to life. Our kit includes 3 ball burr sizes: a 3/8″, 1/2″, and 3/4″. Again, more sizes are available but these three seemed to be the most popular. These tools also need to be used in both climb and conventional directions to achieve the best quality. However, these tools run at a much higher feed rate. We pushed our machine all the way up to 1,200 IPM before quality started to rapidly decline. In my opinion, the feed rates between 250 IPM to 600 IPM looked the best, so I would stick there.

Step 4: Knife Cutting

For those of you that have a knife cutting option on your CNC machine, this will be the easiest part. Simply load the correct oscillating blade and slice through it with ease. If you need blades for your Multicam, Zund, Kongsberg, Colex, Ecocam, AXYZ, Aristo, ESKO, or something else just let us know. We have high quality and affordable compatible blades HERE.

Conclusion

All in all, EVA foam for marine flooring can be cut and shaped many different ways. However, this is a simple and proven method, so hopefully this saved you a little time trying to figure out how to do it. Please note the information above applies to the industrial CNC router and knife cutter world. If you have a table top machine, the feeds and speeds may be completely different.

If anything here was explained too simply and you need any assistance or you have questions about the kit, please reach out. My contact information is below.

Greg Smolka

Greg Smolka (Author)

CNC Tooling & Applications Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and applications (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com | (616) 502-7277 | LinkedIn

If you have any questions about which tools to use for any other project as well as how to program them for success, feel free to reach out anytime. Thanks for reading!

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CNC Routing: Composite Decking Boards

CNC Routing Composite Decking Boards 5

Composite decking boards were first developed in the late 1980s and early 1990s as an eco-friendly, low-maintenance alternative to traditional wood decking. Pioneered by companies like Trex, the earliest composite boards were made from a simple blend of wood fibers (or wood flour) and plastic (usually recycled polyethylene, polypropylene, or PVC), offering resistance to rot and insects, but often prone to fading, staining, and mold. In the mid-2000s, the industry introduced second-generation “capped” composites—boards with a protective polymer shell—significantly improving durability and aesthetics. Over time, manufacturers refined the materials and processes, leading to more realistic wood-like textures, improved resistance to the elements, and a greater emphasis on sustainability by using high percentages of recycled materials. Today, composite decking has become a popular and long-lasting choice for outdoor spaces, valued for its low upkeep and environmental benefits.

With the mixture of plastics and wood fibers, the question “how do I cut this?” comes up often. The easy answer is, with a CNC router bit of course! Choosing the correct one is the hard part which is exactly why I write these articles. We like to scrap chip-load calculators, throw any and every tool at a specific material, then optimize the best performing one.

Thanks to the CNC routers from Specialty Machinery Inc., we were able to do testing on both their Specialty Cutting Systems Legacy router as well as the Kimla Regency router with the exclusive MagLev™ technology.

Depending on the composite decking board thickness, you can choose the Razor Series tool diameter that fits your needs. In this case, we cut 1/2″ decking with a 1/4″ 3 Flute Spiral Upcut endmill called the XR2062-CB. This tool is meant to cut fast without sacrificing edge quality, and it did just that.

This tool optimized out at 200-300 IPM, 21,000 RPM, Climb Cut, at 2 passes. The 3/8″ version of this tool was able to cut it in one pass. The edge quality came out great and the speed was unmatched by any other tool. The Razor series bits were invented to cut Corian material (see our article on Corian material) but they do a phenomenal job with plastics and foams as well. In second place, the Omega Series cut these boards with great quality but at a lower feed rate.

Quick Facts

  • Endmills: Razor Series
  • Specific Tool: XR2062-CB
  • Spindle Speed: 21,000 RPM
  • Feed Rate: 200-300 IPM
  • Direction: Climb
  • Number of Passes: 1 to 1.5 times the diameter of the tool
Greg Smolka

Greg Smolka (Author)

CNC Tooling & Applications Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and applications (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com | (616) 502-7277 | LinkedIn

If you have any questions about which tools to use for your project as well as how to program them for success, feel free to reach out anytime. Thanks for reading!

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CNC Routing – Steel Composite Material

CNC Routing Steel Composite Material

At CNC Tooling Shop, we are often asked if it’s possible to cut steel composite materials, such as Duraplate or Maxmetal Element, on our CNC Routers. I’ve heard conflicting statements, so I thought I’d do some testing and share the findings. The goal was to not only cut the material but to also find out how the tools fare and find the optimal feeds and speeds to achieve the best quality. A customer sent us some Duraplate and we were off to the races.

Duraplate composite panels were invented by Wabash National in Lafayette, Indiana (1996) for freight trailers, truck bodies and portable storage containers. It consists of two skins (80,000 psi-yield galvanized steel) that sandwich a high density polyethylene core. Coatings on the steel insure longevity and corrosion protection. It doesn’t absorb moisture and beats out the previous method of using plywood or fiberglass reinforced panels that rip and splinter. Since this creation has come about, other applications include military, building, storage, and industrial products.

With an array of research and testing, we found that the Saber Series four flute coated bit from X-Edge Tools worked the best. The bits were created to cut Steel Composite Material. The coating makes them durable and long lasting. No other CNC bit, that we tested, offered anywhere near as well of a finish.

XS2052 (Saber Series) 1/4″ Diameter

Results explained:

Routing the Duraplate at 114-200 IPM / 14,000 RPM with XS2052 (BUY HERE) worked perfectly once we found out that climb cut was the proper direction. Our plunge rate was 70 IPM and we used an alcohol-based misting fluid called Liquid-X (BUY HERE). It left behind a healthy chip size and a clean cut. We started with a 4’ X 4’ square and cut smaller and smaller squares until we only had 6” by 6” left. The bit we used could have cut much more before finally getting dull, so we can assume that the tool life is acceptable when cutting at proper feeds/speeds.

Duraplate Cutting Chips

We also tried cutting at different feeds and speeds, without luck. Cutting faster resulted in the spoil board burning, decreased cut quality, and a loud screeching sound from the tool hitting the material. I would expect the tool to wear out very fast if used faster than recommended as well as being a fire hazard. Cutting slower than recommended didn’t leave as nice of cut quality and could possibly lead to tools breaking and wearing fast.

Cutting Duraplate Too Fast

Quick Details / Recommendations:

  • Material: 6mm steel composite material (Duraplate)
  • CNC Bit: X-Edge Tools # XS2052 (BUY HERE)
  • Feed Rate: 114-200 IPM
  • Plunge Rate: 70 IPM
  • Spindle Speed: 14,000 RPM
  • Number of Passes: 1
  • Misting: Alcohol-based Misting Fluid (BUY HERE)

Stay tuned for many more articles to come related to CNC routing from CNC Tooling Shop. We will also be sharing videos and updates on our (and Specialty Machinery Inc.’s) social media pages. Stay up-to-date by following us on LinkedIn, Facebook, or YouTube.

If you need any help with cutting specific materials on your CNC machine, please call me at (616) 502-7277. I manage the tooling department, where we distribute CNC tooling for an array for CNC machinists and companies. We are known for but not limited to working with brands such as X-Edge Tools, LMT Onsrud, Techniks, Whiteside, LMT Belin, Amana, Monster Tool Company, and more. Thanks for stopping by.

Greg Smolka (Author)

CNC Tooling & Application Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and cutting recommendations (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com

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CNC Routing: Corian Solid Surface

Corian is a solid surface material that is composed of approximately one-third acrylic resin (PMMA) and two-thirds natural minerals, primarily alumina trihydrate (ATH) derived from bauxite ore. In addition to these primary ingredients, Corian may also contain trace elements of iron oxide black, carbon black, titanium dioxide, colorants, and methyl methacrylate.

Because of this intense material makeup, people are often unsure how to cut Corian material or question whether or not their CNC router can cut it. The short answer to this question is that your CNC machine can absolutely cut Corian and cut it well. When you pair the correct endmill and feeds/speeds, this material cuts like butter!

CNC Routing Corian

For this test cut, we used The Legacy a Specialty Cutting Systems 4′ X 8′ CNC router with it’s stock 12 HP spindle, max 24,000 RPM. This machine offers more than enough power and speed to cut solid surface material.

The Legacy router has an automatic tool change but all we needed here was one tool. Depending on the Corian thickness and design, you can choose the Razor Series tool diameter that fits your needs. In this case, we cut 1/2″ Corian with a 1/4″ 3 Flute Spiral Upcut endmill called “XR2062-CB” This tool is meant to cut fast without sacrificing quality and it did just that.

We set this tool up to cut the part out at 300 IPM, 22,000 RPM, Climb Cut, and 2 passes. The edge quality came out great and there was little to no sound while this material was being cut. The Razor series bits were invented to cut Corian and we have yet to find an endmill that does it better. If you have some solid surface to cut, give us a call and find out with of the Razor series bits we would recommend as well as the specific feeds/speeds that would work best for your machine.

Quick Facts

  • Machine: Specialty Cutting Systems : “The Legacy”
  • Endmills: Razor Series
  • Specific Tool: XR2062-CB
  • Spindle Speed: 22,000 RPM
  • Feed Rate: 300 IPM
  • Direction: Climb
  • Number of Passes: 1 to 1.5 times the diameter of the tool
Greg Smolka

Greg Smolka (Author)

CNC Tooling & Applications Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and applications (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com | (616) 502-7277 | LinkedIn

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CNC Tool Holder & Collet Maintenance

CNC Tool Holder And Collet Maintenance

Taking proper care of your collets and tool holders will not only increase the life of your collets and tool holders but it will also increase the life of your CNC router bits and spindle. This will in turn improve cut quality and performance. I like to think of tooling maintenance like changing the oil in a car. Sure, the car will run (for a while) without changing the oil. However, there is a risk of blowing a gasket and warping other parts of the engine until it ultimately fails. The same goes for a CNC router. The more time a spindle is in use while being out of balance, the more of a chance it risks failing. For those of you who want to get the best out of your CNC machine investment, let’s discuss tooling maintenance.

Did you know that both the collet and tool holder have a life cycle? Collets should be replaced after roughly three months. They can be damaged or compromised without any visible signs. A very common problem is metal fatigue which can be caused from overtightening and/or cutting pressure. Be sure to use a torque wrench and tightening stand to escape this problem.

Regardless, over time the gripping power will reduce with use and heat. This is why it’s very important to replace these in a timely manner. Tool holders, on the other hand, have a much longer life cycle. They should be replaced every one to two years. Like the collets, these will break down over time. Fretting and bronzing are common as tool holders get older. This is all of course dependent on the use of these tools. If a collet and tool holder is only used for an hour a week, then yes it may last longer. However, that’s if the collet is removed from the tool holder and both are cleaned and kept in a dust-free area. I have a habit of cleaning my tools after every use then putting them back in the original packaging. Not every operator has this luxury because of time constraints. So, for most of you, replacing them in a timely manner, even if they aren’t used as often, is the best option.

Besides replacing these parts when needed, It’s also important to take care of them while in use. Proper cleaning is essential for reaching full life cycles of each and achieving best cutting results. Here are the cleaning steps that should be done on a regular basis. This should be done every time a tool is changed or replaced from a collet/tool-holder.

Step 1

Use air to blow off as much from the tool holder and collet as possible. Blow off any debris, dust, and material chips. Build up often happens within the gaps of the collet. Not blowing these out could cause the collet from not being able to tighten properly.

Step 2

Use a clothe rag or paper towel to wipe off any leftover dust or material chips that are stuck to the collet and tool holder. Sometimes using a folded piece of paper will help get hard to reach chips lodged in the collet gaps.

Step 3

Use the Spindle Wiper Kit to clean out the spindle opening, tool holder opening and center of collet. These are made to clean the hard to reach areas. This is especially important in the spindle and collet opening because they are nearly impossible to clean without this kit.

Step 4

Use the Nu-Tool Cleaning Protectant & Rust/Debris Remover to thoroughly clean the collet and tool holder. The rust/debris remover is only needed when rust or heavy debris are present on your tooling. For the most part, the protectant is the go-to product. This should be used to aid in cleaning every time a CNC bit is replaced. At the minimum, these should be cleaned weekly to get the most out of your tooling.

If these steps are regularly taken, you will get the most out of your collets and tool holders. Your cut quality will be the best that it can be and your spindle will be in balance which in turn will allow it to last longer. Again, treating your machine like you would a car by giving it regular maintenance will help you get the most out of your CNC machine investment.

If you have any questions about this process, the products, or would like me to examine your tooling, please email me at greg@cnctoolingshop.com or call me at (616) 502-7277.

Greg Smolka

Greg Smolka (Author)

CNC Tooling & Application Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and cutting recommendations (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com

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CNC Routing: 6061 Aluminum

CNC Routing 6061 Aluminum

If you own a CNC router, chances are, you have or have thought about cutting aluminum. Whether it be for signs, fabrication parts, automotive, or something else, learning to cut aluminum is a great skill to have. Today, we dive into cutting 1/2″ 6061 Aluminum on a Kimla BPF CNC Router with a 3/8″ Two Flute Upspiral Bit and Alcohol-Based Misting Fluid. CNC Routing: 6061 Aluminum

First off, let’s dive into Aluminum and what to know. The grade of aluminum changes everything! Softer grades, such as 3003 series, needs to be cut at a slower feed rate and most commonly with a single flute CNC bit. Higher grades, such as 6061 series, needs to be cut at higher feed rates and can handle a CNC bit with more than one flute.

Misting fluid is a necessity, not a choice! Whether you’re using an alcohol-based or veggie-based fluid, do not skip this step. There are of course exceptions to this rule, like any, but most of time it is absolutely a requirement. The friction produced from carbide endmills cutting through aluminum sheets, generates heat. Heat is the enemy, which is why misting fluid is so important.

Lastly, material hold-down changes everything. This is important for cutting any material but even more when it comes to aluminum. When parts are not held down properly, it causes chatter, which generates more heat and in turn decreases quality as well as the life of the bits being used.

6061 Aluminum

Type of CNC Router

For this project, we used the Kimla BPF Router. Kimla CNC Routers are currently the hottest routers on the market. They’re in a league of their own due to precise and intentional manufacturing. Customer needs are always at the forefront, which is why we have no problem recommending them to any and everyone. If you’d like to learn more about the Kimla machine line, reach out to Specialty Machinery Inc.

For the most part, Aluminum is cut on a CNC router with a few select CNC bits. We found that the best bit for high speed and top-notch quality on 1/2″ 6061 aluminum was the XV2033 and pairing it with Liquid X, a misting fluid by X-Edge Tools. The XV2033 is a 3/8″ two flute up-spiral tool made for cutting aluminum with a 5052 series grade or higher. The extra flute allows for feed rates to be increased and the up-spiral direction provides great quality. Liquid X is alcohol-based which combats heat more intensely than veggie-based versions and our go-to misting fluid at CNC Tooling Shop.

CNC Routing: 6061 Aluminum

For this project, a full cut-through was all that was needed. We could have drilled holes, beveled edges, or something else but we chose to focus on quality and precision. Our goal was to not only make jumbo puzzle pieces but to also have them fit together much tighter than a glove. We set the Liquid X misting fluid at a standard medium-spray aimed towards the flute of the bit as well as at the top of the material. Our feeds and speeds for the 3/8″ two flute up-spiral bit (XV2033) were set at 22,000 RPM and 150 IPM. For this tool, conventional direction is optimal. We also setup a sloping lead-in and cut through the 1/2″ in three passes to ensure high quality and precision.

Cleanup Pass

After this, we did a cleanup pass using the same bit (XV2033), shaving off an extra .03″ from the edge, to leave a clean finish. For the cleanup pass, we changed the feed rate to 75 IPM and left everything else the same. These parts came out phenomenal! They wouldn’t fit together unless they were perfectly leveled. Once leveled and pressed together, you could hold them all up together by only grabbing onto one of the pieces.

Feeds & Speeds

  • Cutout: XV2033 | Feed Rate: 150 IPM | Spindle Speed: 22,000 RPM | Direction: Climb | Passes: 3
  • Cleanup (.03″ Removal): XV2033 | Feed Rate: 75 IPM | Spindle Speed: 22,000 RPM | Direction: Climb | Passes: 1

Feel free to reach out with any questions or requests for tool recommendations for cutting 6061 aluminum, other grades of aluminum, plastics, composites, or woods.

Greg Smolka

Greg Smolka (Author)

CNC Tooling & Applications Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and applications (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com | (616) 502-7277 | LinkedIn

XL001 LIQUID X

XL001 LIQUID X

$124.00

Misting fluid for assisting in the cutting of aluminum, steel composite materials, etc. by cooling down the cutting process and minimizing heat buildup.

SKU: XL001
Category: ,
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XV2033 3/8"

XV2033 3/8″

$105.00

2 flute upspiral for ALUMINUM, ACM, WOOD, etc

SKU: XV2033
Category: , ,
Tags: , , , ,

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CNC Routing: King Color Core

As the popularity of King Color Core (Plastic) grows, the knowledge on how to cut and shape parts with a CNC router must grow as well. Here is how we created a simple yet eye-catching sign on the Kimla BPF CNC Router with Black & White King Color Core plastic material.

First off, lets dive into King Color Core and the Kimla BPF CNC Router. King Color Core is made with high-impact-resistant polymer, more commonly known as HDPE, to handle more abuse than conventional sign materials. It is durable, never needing refreshing, and versatile with layers of contrasting colors. Each side has a matte finished face. It is environmentally stabilized to withstand the harshest outdoor conditions meaning that it will not rust, delaminate or rot when exposed to UV, humidity, or water.

Various King Color Core Sheets

Ideal applications include:

  • Signage
  • Marine Applications
  • Children’s Furniture & Tables
  • Displays
  • Games
  • Museums

Kimla CNC Routers are the hottest routers on the market. They’re in a league of their own due to precise and intentional manufacturing. Customer needs are always at the forefront, which is why we have no problem recommending them to any and everyone. For this project, we used the Kimla BPF. If you’d like to learn more about the Kimla machine line, reach out to Specialty Machinery Inc.

King Color Core can be cut with an array of different CNC bits but we found that the best one for speed and quality was the XR2062-CB and XR2063-CB which is the Razor Series from X-Edge Tools. This is a three-flute upcut tool with chip-breakers built in, made for cutting plastic materials. The additional flutes allow for higher speeds. The chip-breakers help decrease chip size and material melting. The upcut/up-spiral direction helps this tool provide top notch quality.

Cutting King Color Core

For this project, a simple cutout and v-groove was all that was needed. This material has an array of different capabilities when it comes to tooling options. From roundover bits to keyhole slot cutters, there’s a lot that can be achieved here. First, we engraved “CNC Tooling Shop” into the material with the XIV6012 which is a 60 degree v-groove insert cutter. The replacement inserts in the cutter allow you to cut costs by simply replacing them when becoming dull instead of replacing the entire tool. The sweet spot for XIV6012 was a feed rate of 100 IPM and a spindle speed of 21,000 RPM. Lastly, we cutout the rectangle shape of the sign with the XR2062-CB which, as stated above, is a three flute upcut tool. This tool was ran at a whopping feed rate of 500 IPM and a spindle speed of 22,000 RPM. It’s amazing how well this tool cuts at high speeds.

CNC Routing King Color Core

Standard Cutting Parameters:

  • Cutout: XR2062-CB | Feed Rate: 500 IPM | Spindle Speed: 22,000 RPM | Direction: Climb
  • V-Groove: XIV6012 | Feed Rate: 100 IPM | Spindle Speed: 21,000 RPM | Direction: Climb

Advanced Cutting Parameters (following standard cutting parameters)

  • Cutout Cleanup: (.03″ Removal) XR2062-CB | Feed Rate: 60 IPM | Spindle Speed: 22,000 RPM | Direction: Climb

Feel free to reach out with any questions or tool recommendations for cutting King Color Core, other plastics, aluminum, composites, or wood.

Greg Smolka (Author)

CNC Tooling & Application Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and cutting recommendations (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com