Creating signage using laminated EPS foam

[IlanDeiStudio]

Looking to get some information or recommendations for creating signage using a 2" 2.5lb eps substrate with a vinyl (or another laminate, possibly acrylic or formica) applied to both sides. The issues I'm encountering are the quality of the edge of the foam when milled as well as the vinyl itself getting chewed up when milled. I need a few recommendations on speeds as well. At the moment im using 16K spindle speed with 120 ipm cut feed. In terms of bits I have tried both a single flute compression bit for the laminated material as well as a 2 flute carbide spiral upcut bit. The goal is to place the laminated foam onto the mill, cut, and do little to no post processing. If anyone has any recommendations for different laminates for the foam or any other materials better suited for the application it would be greatly appreciated.

Thanks

Andrew
Ilan Dei Studio
Venice, CA