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Personal view here, but based on using my own machine for the last 2-3 years. It's described somewhere on this forum - search for "AVOR" and my username if you want to look it up. It's built mainly...

You then have to choose what measurements you need to make and instruments to buy in order to set those adjustments correctly. There are a lot of worms in the can but you learn a lot too.

Your concentrating too much on deflection and not thinking about resonant vibrations which are the real killers of tools and finish. That Z-axis shown will resonate because the plate is too thin with...

Well sort of.... The direct fixing of the rails thing was more aimed at how you're spacing the front and back Z plates apart. Currently you have the carriages fixed hard onto the back plate, and then...

Combine both and that's what you will have if you do not design properly the machine.

If you design your Z properly , use proper bearings and mount your spindle correctly, variant 2 will be non...

Glad you found the CNC videos useful. It was a good way to pass on the ideas I had seen, and add some of my own thoughts.

In the analysis:
Yes, vertical direction forces are mostly due to...

Tip: if you can add some bits of bar to stiffen your Z-plate (i.e. turn it into a channel section) you will do better cost for cost than a flat plate. For example a 10mm plate 180mm wide with some 30...

That's about it. just two pieces of 50 x 100 welded together to give 200 x 50. The whole is then welded to the gantry uprights.

Bear in mind that this gantry was the first time I ever tried...

I know you are designing on the basis of 50 x 50 material but rather than the complexity of the braces in the designs above have you considered two pieces of 100 x 50 welded together to give a flat...

Agree with Voicecoil.
Analysis 2 is closer to worst case as this puts a twisting moment on the gantry as the force is applied at some distance away from the structure and will usually cause the...

Setup 2 is much more realistic since you want to design for decent performance when the cutter is hanging down a fair way below the gantry, 'coz that's where it will often be used. Having an equal...