Step 1: CAD/CAM
I did the CAM setup in CAMworks. This was divided into a rough area clearance, a z-level, and a constant stepover finishing pass. I chose to do the rough clearance with a 1/2" hogging end mill, the z-level with a 1/2" regular end mill, and the stepover with a 1/4" ball end mill.
Step 2: Materials
CNC Mill (3-Axis Bridgeport)
1/2" Hogging End Mill
1/2" Regular End Mill
1/4" Ball End Mill
2" x 3" x 5" block of pink insulation foam
2" x 3" x5" block of 6061 Aluminum
I had access to the equipment and materials through my college's machine shop. The foam was just lying around, and the aluminum block was from a discarded bicycle welding fixture.