Need Your Help: Need to Design a Saw with SUPER LOW KERF LOSS

[Educated Guess]

Hi, Everyone. I have a small business that makes expensive guitar picks. One of the materials we use is called DuPont Vespel (pictured below). It is one of the most expensive plastics in the world.



The problem? Let's say I make a guitar pick that is 1.0 mm (.040") thick. I am losing as much in the kerf as I am in the pick. There are some slicing services I've found that can get this down to about .020" (.50 mm) kerf loss per pick, but at $10 a throw it's way too expensive. CNC is also too expensive.

There are small HSS saw blades that go down to .020" or thereabouts, but I need to find a way to mount a blade and do the cut. I thought something like this design, adapted to my specific needs, might work.



I'll figure it out cuz I HAVE to do, but would love to hear your ideas.

Thanks,
EG