Ideal base plate thickness...?

[sugeek]

When I was making telescopes instead of laser projectors, I was cutting 1/4" aluminum plate with several passes of a router with carbide cutter.

Loud! But it works well.

You can actually use a table saw (works for large pieces, this was even done in some R&D labs I know of) no kidding just keep the alcohol spraying on the aluminum cut, it is rough but even a wood blade works (a two person job)... Tomorrow I am cutting a plate but using a jig saw and metal blade (ear plugs too).

-Adam

[Doc]

Our comany always uses circular saws to cut thick alu. The blade has 4tpi for this purpose. Makes a really neat finish.

Example