Careful climb cutting (right to left) of each pin and tail will help significantly to avoid chip out.
Don't try to cut the entire slot. Just climb cut the first 1/8" or so (keep it less than 1/2 of the bit's cutter blade diameter). Then follow by a second cut deeper and counter clockwise into the jig along the the right side guide, across to the left guide and then back out. Do this two step cut for each pin or tail slot that you cut and I'm quite certain that you will see a significant improvement.
Sacrificial strips clamped to both sides of each board as it is cut will also help, but in some cases, when using dovetail jigs, it is not very practical.
The chipping occurs as the tooth of the router bit is exiting the board surface. Climb cutting (moving the router in the opposite direction) will remove the surface wood at the usual exit point before the bit can grab and remove a big piece at this point if cutting in the usual direction, and result in chip out. Once the light climb cut pass is done, the remaining surface wood around the cut area will help prevent further tendency to chip out around the edge of the cut. If you closely watch the Leigh Dovetail jig demo below you will see that they do this climb cut and then go back and remove the rest of the cut in the regular way.
This is actually a video for the Leigh FMT, but it shows climb cutting (Clockwise direction) at 2.00 minutes into it as the first cut of a tenon being made. Then the cut is repeated, but in the (counter clockwise) normal cutting direction to reduce the tenon size to it's final dimension. I'm showing you this video because it's easier to see how little chipping occurs when they are climb cutting, but it's necessary to remove only a little material from the board surface during this climb cutting, because taking a bigger bite will cause the router bit to dig in and pull the router out of your hands. They then show going back and making the second pass to finish the cut, moving the router in the normal direction, where it doesn't try to pull away.
An older video for the D4R Dovetail jig showed this same climb cutting technique being used to cut dovetails and pins, but their latest D4R video that's now on YouTube seems to have left this scene out. Regardless, it is still the best way that I know of to reduce the chip out if you can't use a sacrificial piece.
Central North Carolina
Last edited by CharleyL; 01-22-2019 at 10:10 PM.