I have a production job coming up that will require a shape to be cut out of a part 7-8 inches wide x 16-18 inches long that needs to have fairly sharp points on the exposed face. So imagine a board with an internal shape cut out that has many sharp points. This wont be possible from the front side face with a spindle and would have to be machined from the back side. The customer asked for 3/4" thick material but is willing to go thinner. Our thought was to V Carve these but from the back side. Where the V bit would carve down and pierce barely through the bottom face leaving a relatively sharp point. Those points would be pretty thin and fragile.
There is no entry point for a band blade. Or to have the customer go even thinner (which they dont want to) and have them burned out on a laser capable of the thickest material we can.
I have tossed around hogging out the bulk with a clearance toolpath and doing a finish profile with a tiny endmill but even with a 1/16" (1/32" rad) tapered ball nose you lose any sharp points.
Im overthinking at this point..