I'm thinking about using a 90° V-bit in a profiling toolpath, so I can cut pieces out of 3/4" birch ply that will fit together with mitered edges. When I do standard V-carving of lettering or whatever, the cutting is done in a single pass. However, if I use an end-mill to cut through 3/4" ply, I usually use a stepdown of 1/2" or 1/4" (depending on bit diameter), which results in multiple passes.

Does anyone have any experience with cutting all the way through 3/4" ply, using a V-bit in only one pass? What is the maximum stepdown you'd recommend? How likely is it for the bit to break in this situation?

Thanks for any and all advice.