Quote:
Originally Posted by Owen Busler
We plan to cut this on a router with an 1/8th inch bit and every corner is filleted to a 1/16 radius.
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This is a bad strategy. You should always aim to have your fillets larger in radius than your bit radius unless you really have no work around. The reason for this is because endmills do not like going into a corner stopping, then changing direction. They would be much happier and will give a better finish and less likely to break in corners if they arc through it a little.
I would suggest 0.075"-0.090" radii for an 1/8" endmill.