What I'd do is have the holes rough cut on a CNC plasma table (they can cut 
aluminum, with the right setup) then do full depth profile cuts with the wood 
router gantry.
A lot of those cuts, just past the point of chip thinning. 
http://www.mmsonline.com/articles/the-high-feed-high-reliability-process

If what goes into the holes has sharp corners you can drill them so when the 
end mill makes the turns it's cutting air or you can setup the path for it to 
cut past the corner both directions to leave open areas for the workpiece 
corners to fit into.
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