Cast aluminium gantry router

Hi all,
I'm starting a build thread for my machine and I'll see what you all think of it. I run a small aluminium foundry and a cnc router is something that'll be useful for making patterns for me.
I'm going to be casting a lot of the parts for it and I haven't seen another one like this on here so I hope you'll enjoy.
I've bought the rail, ballscrews and a 2.2kw spindle and VFD, here's the shopping list so far.

SBR20-300/600/1000mm linear slide guide shaft (6 fully-supported rails+12 SBR20UU bearing blocks)
Anti backlash RM1605-350/650/1050/1050mm-C7(4ballscrews+4ballnuts+4endmachinings)
4 sets BK/BF12 bearing end supports with locknuts and circlips
4 pcs 6.35mm*10mm(motor*RM1605) couplers

I've started the pattern to cast the gantry and I'll post pics as soon as I can find the cable for my camera.

I am very intrested in this build, I have often thought about using cast parts for gantry ends and such. Looking forward to seeing the pics and best of luck with the build.

Sounds a very interesting build I so will be watching to see how it goes. I do like the idea of casting some parts.

Once you have successfully cast your parts, do you intend to offer cast parts for sale on the forum? If you do I am sure that you will soon get some customers for gantry ends, motor mounts etc. Good luck. G.

Looking forward to this....always fancied making cast Ali parts...

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Originally Posted by GEOFFREY

Once you have successfully cast your parts, do you intend to offer cast parts for sale on the forum? If you do I am sure that you will soon get some customers for gantry ends, motor mounts etc. Good luck. G.

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I agree, I think specialised cast parts would make for a good kickstarter. I would buy a nice cast gantry end that incorporated machined mounting points for linear bearing blocks and ballscrew mounts

Good idea about the kickstarter, maybe I should keep all my ideas secret in case anyone nicks them :)
Sod it, here's some pics.
Here's the start for the gantry pattern. It's 19mm thick and longer than I need as I'm thinking about doing a kit and the gantry can be cut to size. All needs to be sanded smooth and all the inside corners need to have wax fillets put in.

Attachment 12539Attachment 12538Attachment 12537

Out of interest, is it expensive to get a mold cast if I supply a pattern. Just curious as I have some product ideas?

Good idea and i am interested about the process.
One thing that you should have in mind ( i have read it once in a Greek forum CNC HOBBY - CNC Mills, CNC Lathes, CNC Routers, Metal Casting, Servos, Steppers, Motion Control ) is that after Casting the aluminum shrinks according to a shrinking Factor. That Factor i think isnt stable as shrinking may be affected from humidity, temperature.... So that means that you cannot make by casting parts that have acurate dimensions near 0.1mm. Of course you can make your parts and then mill them to the dimensions that you want.

Good luck and keep trying