End mills overview and usage

Quick links:

• Overview of end mill characteristics
• For 2D routing
  • Plywood
  • Hardwood
  • Plastics
  • Foams
• For 3D milling
• For detailing and engraving
• Where to buy

Overview of end mill characteristics

[TODO: figure out a way to organize this info in an easy-to-read way.]

• Flutes = single, 2, 3 and more
• Flute type = straight, spiral and O
• Nose profile = flat, ball, bull, tapered, V
• Cutting length = the usable length of the tool, excluding shank
• Cutting diameter = 1/8" to 1/2" is common for this size of machine, but can be much smaller or a little bit larger.
• Shank diameter must fit into an ER20 collets, of which we have several, or you can order your own.
• Direction = up, down, and compression cut
• Composition = HSS, carbide, exotic coatings

For 2D routing

In general, stick with flat nose end mills in order to cut all the way through material with minimal spoilboard penetration.

Plywood

Recommendation(s)

1/2" or 1/4", flat nose, 2-flute (spiral). See notes about direction. Might also be able to use conventional hand router bits, otherwise known as single or 2 flute (straight), flat nose.

Notes

Plywoods can be surprisingly tough on end mills due to resins. MDF in particular is very rough on end mills, as the fine dust can function as gritty abrasive. Use something that is cheap enough that you won't be frustrated by dulling, but good enough quality that things aren't harder than they have to be. Direction Up cut can lift workpiece and/or cause ugly tearout on top surface. Down cut won't lift workpiece, but can cause ugly tearout on bottom surface. Compression cut is ideal, but more expensive. A cost effective compromise is to use down cut on first pass(es), then up cut on final pass. Composition Use carbide end mills. Avoid HSS. Save yourself money by not springing for exotic coatings.

Hardwoods

Plastics

Recommendation(s)	For soft plastics: 1/4" or 1/8" single flute, up cut, "O" profile
Notes	Softer plastics tend to produce long curls rather than chips. Single flute "O" profile tends to keep these curls nice and long, while the up cut direction moves them away from the workpiece, preventing them from welding back onto the workpiece.

Foams

For 3D milling

In general, stick with ball nose end mills.

Recommendation(s)	1/8", 2 flute, ball nose for coarse details. 1/16-1/64", 2 flute, ball nose, tapered end mill for fine details.
Notes	On larger jobs it can be smart to use multiple passes with different tools. For example: Roughing pass with largest available end mill. Coarse detail pass with a 1/8" end mill. Fine detail / finishing pass with a 1/16-1/64" tapered ball nose end mill.

For detailing and engraving

• V bits are popular for classical signage, but also impose a strict (though sometimes desirable) aesthetic.
• Small diameter means finer features.
• Look into PCB isolation / micromachining bits
• Flat nose probably preferable to ball nose.
• Flutes probably don't matter as much.

Where to buy

• McMaster
• ToolsToday
• Carbide3D
• Inventables