Thanks for taking the time to screw around with it. Seems like you had similar results. I wonder how a blade with an abrasive coating vs teeth would work. I will monkey around some more this weekend.Originally posted by buscht
So my recommendations based upon a grand total of 1/2 hour of messing around.
1. You can use a scroll saw with fair success. I don't know if this application can be CNC'd with a scroll saw as you need a spiral type bit and I don't know if such a bit is available with a fine enough tooth to cut well.
2. Other options for cutting this material. a hot wire, similar to used on foam cutters. Maybe someone with one of these machines could test this out.
I think a water jet or laser would cut this material, but you would be into a commercial application, not a DIY job.
This is very much outside the box thinking when compared to a CNC router, but I am 99% sure it would work. It might be too time and cost prohibitive to develop however. Especially when you mentioned that you didn't have much time available for experimentation.
Good luck.
T