Utabintarbo pointed out to me this morning that the 1/8 channel that the minimum endmill dictates is too large, and after recalculating (I made a sum error), it's apparent that there would be only 8 fins left (and 8 posts on the outer edges, maybe).
So the CNC option is out, unless someone's got a very high speed (10'000 rpm??) CNC setup that can handle a 1mm endmill.
In the mean time, I've been exploring the possibility of dremelling this thing by hand. I found plenty of bits at
www.widgetsupply.com but I'll need to run this by you guys:
Here are the bits I picked out, and pics:
type: Diamond burr
Cylinder shaped diamond burr, 1/16" in diameter x 1/4" long, with 1/8" shank.
type: Carbide burr
0.8mm x 3.6mm Densply Maillefer Cylinder Carbide Burr, 1/16" shank. Approximately 3/4" overall. Made in Switzerland.
type: HSS
0.8mm x 4.1mm Densply Maillefer HSS Cylinder Burr. 1/16" shank. Approximately 3/4" overall. Made in Switzerland.
The pink stuff is a lubricant.
My little Dremel is rated to 35'000 rpm, but with little power. My question is: can I do this, in 1 mm, with the right Dremel?