I sort of want to stay away from MDF because the dust is really nasty to breathe in. I sort of have a good dust collection system in place and wear a respirator mask during clean ups but I would rather just not deal with MDF all together because of how harmful they can be.
Are there any other good materials that you guys would recommend cutting with for doing prototypes/modeling?
Polyethelene plastic would fit this bill. UHWM plastic in some formulations. You can get big blocks of it “natural” off ebay. It machines extremely easily and takes fine detail well.
Not sure where you are located but you can go to Home Depot and purchase PVC trim board in various lengths and widths.This stuff machines beautifully. I use it for prototyping fishing lures