Abstract Unconventional oil and gas exploration has created ever-greater demands on milling technology as wells have gone deeper and the number of frac zones has increased. A new cutting element has been developed that can mill up to double the previous number of composite plugs or frac seats, allowing most wells to be milled in a single trip. The previous record for the most plugs drilled out with a single mill was 40. A mill dressed with these new elements removed 79 plugs in two different wells, and it holds the record for the most plugs removed from a single well after drilling out 52 in a single trip. Before this innovation, 30 frac seats were considered to be the limit in one trip. In the first five wells this element drilled 40 seats out of each well in a single trip. Window mills with these elements have cut the first full-gage windows. Mills have been pulled with negligible diametral wear from a number of shale and limestone exits. This was achieved with multiple rows of cutting elements. The first row was damaged, but the additional rows were intact. The piéce de résistance occurred on March 20, 2013. The thickest casing in the world, used in massive salt formations that collapse ordinary casing, has challenged casing exit systems for decades. Exits out 7⅝-in. – 59 lb, 0.812–in. thick wall casing were cut in two trips with PDC mills; one trip to cut the window, and a second trip to fully open the hole and finish the rathole. The drilling bottomhole assembly (BHA) had long, large diameter directional elements, so a smooth, full diameter window was required. The mill dressed with the new cutting elements completed the exit and the rathole in the first trip. On the second trip, the assembly slid all the way to bottom without drag. One low cost carbide mill replaced two PDC mills. Conventional mills typically leave thin steel flaps or sharp lips at the top and bottom of the window that can stick and/or damage the drilling assembly. Full scale rig tests have shown the new technology produces smooth edges at the top and bottom of the window. The design of high-impact cutting elements required for many oilfield cutting applications is uniquely challenging. The elements must present an effective cutting edge regardless of orientation, have the same height whether standing or leaning, withstand substantial impact, have relatively low cost, and above all, have a long life to avoid a second trip. Element design and case histories from frac plug, frac seat, casing exit, and drill pipe milling will be included for review and discussion.