Isn't it funny how folks from different backgrounds make different assumptions from posts? :-)

I read "laminates" to be Formica or Wilsonart plastic laminates (stuff that you would put on the surface of a table or cabinet). Phenolic would have never crossed my mind.

Rigid phenolics actually melamine in most cases is fairly easy to engrave with carbide tools. Rigidity of bottom loading spindle helpful on small letters to reduce chipping. Nose guards can often scratch the finish so watch out.

Sharp cutters and lots of spindle speed. I believe the surface speed recommended for phenolic is 1200 surface feet per minute. so the speed for an .02 tip would be over 200,000 RPM. I have seldom seen it necessary to drop spindle speed below 20,000. If you don't have strong enough table motors you might have to lower speed to keep from burning light colors. THe highest feed rate that gives an acceptable letter will give the longest cutter life because abrasion is the biggest cutter problem.

We normally cut thourgh 1/16-inch in two passes. One about .05 deep then through on the finish cut. We frequently use tapered cutters say 10 degrees per side and the bevel is unnoticed and cutter life much longer than parallel cutters.

Hi David

Yes - the material is Phenolic. The scraps I have are 5 ply - there is a black core, red layer and then white outer layer.

I broke two 'router mills' last week when using them for the 1st time with some brass. I went straight back to trusty my paraller cutters. I will stick to these or the approach Joyce gave.

I am so pleased I bought a cutter grinder recently - makes things so much more flexible.

I apologize for the delay in responding. I didn't receive an email notification and haven't been on.

Size the tip for the depth you are going (1/16, 3/32, 1/8 or ?), the spindle power available and toughness of the material. We generally use .01 to .06 tip.