Aluminium Profile Type Router - Initial questions

[CNCRY]

It's not the best of ways but if you bolt the profiles together along there length as well as the ends it should be ok. Obviously, because the slots don't line up you won't be able to use the slots to lock together but you should be able to drill and tap them together from underneath with a few bolts.
Don't use adhesive.!!




Cast plate isn't required but the plates must perfectly flat with parallel faces and exactly same thickness on both sides of machine. Rolled plate isn't flat or with parallel faces so unless you machine it flat and parallel then ground plate is your only choice if you want it right. Why 50mm thick.?



Try to keep the holes to correct size if possible. Only make oversize if needed.
When I say adjustability I mean don't machine plates with slots etc that lock things together unless the whole machine is built this way and on an accurate machine. Adding plates or brackets that allow adjustability is always a good idea. When making plates etc then adding slots rather than holes can help in some places but depends on machine design.

One of my methods is to use slots to allow adjustabilty then when it's all setup I'll lock it in place using tappered holes and pins.



Wouldn't use anything else. These work well and allow AC or DC with voltages upto 70Vac or 100Vdc. This means you'll get good speed and with 5.5Nm you've plenty of power.
If you go for the lower powered motors just check the drives Max voltage because a lot of them are 50Vdc Max which will limit your speed.

https://www.aliexpress.com/item/3279...44bf3421SaYv5O

I did some more thinking on 2 profiles with different spacing - as the 2 do not need to align on the face in the design, I can offset the top piece by 5mm so at least the front slot is in line, then bolt/tap the rear.

OK great - I'l either go for Ecocast or see if I can get it milled. Its 50mm thick as the block is intended to add some Z clearance for the gantry. Without it clearance is only about 100mm, so takes it upto 150mm .



Hybrid Steppers are slightly more reasonable price then I had expected Vs standard steppers. Looks like the LC60H2102 (4.5Nm) and LC60H2112 (4.8Nm) both also support 100VDC with the same LCDA86 Driver, although strangely are twice the price as the 5.5Nm from what I can see!
Would the 5.5Nm be overkill on the Z axis ?
I noticed the 5.5Nm has a 35mm shaft and keyway, which should help with pulley mounting. How does that work with direct coupling though, a keyway and standard shaft coupler?

Thanks