Step 1: CAD it up -- pick material
For the material, I looked through the TAP plastics samples, and decided on the 1/8" P95 acrylic green edge with a haze finish on one side. It basically looks like sandblasted glass -- pretty slick-looking stuff.
Step 2: Testcuts
for the 1/8" P95 I ended up using the following settings:
speed: 7% -- Power:100GW -- Freak:5000 Hz
Speed: 50% -- Power: 30
The part I messed around the most was the cutting speed -- anything faster moving or lower frequency produced a non-smooth cut making the surface of the cut appear less like glass and more like molten plastic (like in the photo). Slowing it down and cranking the frequency gave good results. Do a bunch of cuts on a scrap piece and write down what settings.