In extruded polystyrene foam. Going to make in MDF when I get I a dust shoe on the machine.
troughs:
3/4" 2-flute carbide ball-end router bit
10,000 rpm (probably could have been faster, but cut fine)
22 ipm plunge and feed (could have been faster too)
cut at full 0.250" DOC
outside:
1/4" 2-flute carbide upcut bit
27,000 rpm
60 ipm plunge and feed
0.615" DOC (material is 0.595" thick)
used some 1/8" x 1/8" tabs