The User Language Program outlines.ulp implements the entire process necessary to do this. The following is a detailed description of what exactly has to be done to produce outlines data with EAGLE.
Preparing the board
Outlines data is produced by defining a POLYGON in the layer for which the outlines shall be calculated. This polygon must have the following properties:
Extracting the data
The outlines data can be extracted from the board through a User Language Program. The outlines.ulp program that comes with EAGLE implements this entire process. If you want to write your own ULP you can use outlines.ulp as a starting point. See the help page for UL_POLYGON for details about how to retrieve the outlines data from a polygon object.
Milling tool diameter
The diameter of the milling tool (and thus the Width of the polygon) must
be small enough to fit between any two different signals in order to be able to
isolate them from each other.
Make sure you run a Design Rule Check (DRC) with all Clearance values for different signals set to at least the diameter of your milling tool!
Non-zero values for the Isolate parameter can be used when working sequentially with different milling tool diameters in order to avoid areas that have already been milled.
Make sure that you always delete the _OUTLINES_ polygon after generating the outlines data. Leaving this polygon in your drawing will cause short circuits since this special polygon does not adhere to the Design Rules!
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