A couple of beginner questions... Profile sizes and cutting area size.

[JAZZCNC]

1. What is the maximum cutting area I can expect to have if I don't want to have a Y axis that has dual steppers? I hope that's the correct way to phrase the question, from my basic understanding once you get past a certain size I thought the Y axis needs two linked/synced steppers?

For a router cutting mostly wood, plastics and the occasional bit of light aluminum work then wouldn't go past 700mm cutting width with a single screw. However, the gantry design comes into play as well and needs to be built a little stronger as you get wider.

2. What size profiles would I likely be looking at if I wanted to build a machine chassis to the above requirements... 4080, 4590, 5050 etc, etc.

I appreciate that the last question might be quantified by other design considerations, but again just wonder what people would consider the minimum sized profile to guarantee a decent base level of rigidity.

45x90 or 40x80 is a minimum I would use and again depends on the machine size and design. To give you some idea this machine design I build use's only 45x90 and it will happily cut everything up to aluminium.

The machine in the picture uses a single screw and as a cutting area of about 600 x 1000 if I recall correctly. However, I've built lots of machines with this design up to 700 x 1250 cutting area using single screws. If you wanted stronger machine at the same width/length say for cutting mostly aluminum or Hardwoods with heavy cuts then go with twin motors every time.