Recommendations for a 1/4" cutter to cut plexiglass/acrylic/plastic?
I have the Amana O flute in 1/8 and 1/4 and love them. 51524-K is the 1/4" coated version, 51445-K for the 1/8". I use them for cast acrylic, Corian, and HDPE. I would suggest ramping for non-thru cuts as plunging can leave witness marks on the floor of a pocket or Advance V-carve, easy to sand but extra work.
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The only plastic I’ve cut so far is HDPE. I also use the 51524-K and 51445-K from Amana. I’ve also had good luck with Speed Tiger O-flute bits they are a bit cheaper than the Amana if you are buying them individually, but the plastic cutting pack Carbide 3D sells is a pretty good deal for the pair of Amana bits.
At least for HDPE you really need to get aggressive with the speed/feed rates and especially the plunge rates. If you are making very fine strands they will tend to wrap themselves around the cutter into a birds nest you’ll have to pause and clean regularly. Even with aggressive cuts this happens, but not as often as the bigger strands will tend to break up with the centrifugal force.
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I cut a lot of plastic (acrylic, polycarbonate, ABS, HDPE, others I’m forgetting) and I use the Amana single flutes for 1/4" and 1/8" diameter endmills.
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