Full DOC in aluminum?

Did you mean chipload ? (0.001" being the golden value for aluminium). For optimal load (i.e. stepover) something like 0.01" or higher would be more like it.

For what was one of my first aluminium jobs I remember cutting full depth 0.4" stock (so a bit more than 3/8") using an adaptive toolpath, for the fun of making those long chips:

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but the pros here have proved that using a lower DOC and more aggressive feeds and speeds is more efficient on a Shapeoko in most cases.

Share your full feeds and speeds and setup (air blast ? lubrication ?) to troubleshoot what may have happened ?

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