Thanks for posting this info. So incorrect feedrate is definitely your problem: CC recommended a spindle speed of 9375 (which is not even achievable on a Makita router, let alone a Dewalt router, I wish CC did not do that to users…), but by setting your Dewalt on 4, you actually had a spindle speed of 21500RPM, more than twice more than intended. And the CC recommendation was borderline too slow in the first place (19.5ipm at 9375RPM with a 2 flute endmill is 0.001" chipload, which really is the lower limit for cutting plastics). By running your job at 21500 RPM and 19.5ipm with the #102, you had a chipload of 0.0004" chipload, and that is definitely too small.
The remedy is to feed faster, to get back into 0.001" chipload territory. There’s a simple rule you can apply, that if you cannot reach the RPM setting CC is recommending, just multiply BOTH the spindle speed and feedrate by a given factor, and this will maintain the same chipload.
So in your case, assuming you stay at speed 4 on the Dewalt, the RPM “correction factor” is 21500 (actual RPM) over 9375 (intended RPM), that’s 2.29. You then need to increase the feed rate value in CC by at least that, so 2.29 * 19.5 ~ 45 ipm. That should work (at least much, much better than running at 19.5ipm, but if I were you, and considering your shallow depth of cut (0.03’’), I would push that to x2 the feedrate that CC recommends, to get a chipload of 0.002’’. And that’s how you end up with the ~90ipm value I was recommending in the earlier post.
So long story short : only modify feed rate from 19.5 to 45 in your project, and rerun. If the cut is still not perfectly clean and/or your are not getting nice snowy chips, increase feedrate again (keeping everything else the same), up to 90ipm if that is what it takes.