I grabbed several sheets of Hex Ply in various thickness to try out some ideas. Ply is faced with phenolic film, one side in a hex pattern - used for truck trailer decks and in my case flight cases and equipment racks among others.
Designed a small router table inspired by several models and cut it from the 18mm ply. Total cut time around 45mins with a 3.15mm single flute at 80mm/sec DOC 3.5mm. Had to get a little creative in Estlcam to achieve ‘hole in a pocket’ cutout.
Pretty pleased with the result - no tear out on the top film even with the upcut bit.
Still waiting on specific fasteners to assemble the prototype equipment racks - pics shortly