The problem you are trying to get away from "tool marks" in the injection molding we have to polish them out. You may be getting excessive ones because the head of the router is not sturdy enough for aluminum and is getting torqued and then cutting with one half of the diameter leaving a spiral mark in the aluminum. In most cases when we produce an aluminum tool we use carbide in a steel cutting machine. In a few min with a good polisher he can remove all tool marks in several square inches. He can also take air hardened H-13 to a mirror finish in a short amount of time. Let me know if I can be of any more help [email protected]
Jetski (alias Tooling and Engineering Czar)
"I may not have the keys to success.. but I have learned to pick the locks"