mcdanlj,
@mcdanlj@social.makerforums.info avatar

@kbob @smellsofbikes @chrishuck I used a sketch to look at what the cutters would have to look like. For my example 4mm high dovetails 15mm max width, 30° angle, and a 60mm outside box with rotation point 4mm inset in both X and Y in from the corner, it looks like if one used straight cutters instead of curved cutters, the max deviation from the defined curve would be about .016 mm, which in reality would be half of that if you split the difference top to bottom. In imperial, that's about 3 tenths (ten thousandths of an inch) which is beyond the skills of most home gamers like me.

Also, good luck finding a set of 10.736°, 17.541°, 30.399°, and 30.965° dovetail cutters off the shelf! 🤣

Realistically, I do wonder how close the most extreme angle would have to be to deceive the eye on casual inspection. Especially after some creative deburring work. It doesn't have to be straight, it only has to look straight.

Extreme close-up view of dimension showing max deviation of chord from conic section

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