There are some issues with size consistency. I am wondering if I am running with too much resistance on the machine. My next step unless anyone else has suggestions is to slow down the cut or take shallower passes.
Of the 5 sets of scales, the total sizes differ by almost a millimeter. Photos below show a set of scales on laser cut liners from sendcutsend.
Shallow cuts, and do a full-depth finishing pass. Don’t try to cut the shape without using a full depth finish at the end.
I cut a lot of composite materials, and the type of milling operation is also important: Conventional, vs Climbing. One of them pulls the bit into the material and If you only make one cut (without the finish cut) it tends to make the part undersized. The other type pushes away from the part and tens to make it oversize.
Of course that depends on whether you’re making an inside or outside cut. I can never remember which does what, so I always do a finish pass.
