600x900 Steel welded router build

[embraced]

Hi all,

After getting discouraged on a recent mill build (due to several factors), I've set my sights on making a second router to distract myself from the mill.

The first router was a R&P machine driven by AC servos and a smooth stepper. In the process of building it, I learned an incredible amount - this new build will build upon that knowledge.
(early) pics of said machine:
My main complains with that machine was the lack of stability with the Servos (due to several reasons), flimsy legs, R&P transmission and the awful problems I experienced with mach3/smoothstepper.



The new machine (the topic of this thread) will be much different:

• 600x900*150 work area (or there about...)
• Hybrid servo driven (4.5N.m closed loop steppers on X and Y, 2.0N.m on Z)
• 2510 double-nut ballscrews on X and Y (Y axis is dual-driven)
• 1605 double-nut ballscrew on Z
• 100x100x6 hollow-section steel used for entire frame
• Welded construction
• Gantry will be 150x100x6 hollow section
• Linear profile rails on all axes (20mm on X and Y, 25mm on Z)
• Laser-cut brackets
• Aluminium profile table top
• Possible sand/epoxy sand fill
• Controller will NOT be mach3. I will probably get a Chinese stand-alone controller (the ones with the screens and controls on one unit)
• Spindle has yet to be decided on - I'd like to get an ATC spindle with a ISO20/ISO25/BT30 nose. Having a fixed collet chuck is truly a productivity killer.

Current weight (pre-sand/epoxy fill) is estimated by Solidworks to be 330kg. This is without a spindle.

Solidworks renders:



There are some details in the photos that have not been detailed yet, notably:

• How the Z axis ballscrew is coupled to the motor (will be belt-driven, probably with an HTD3M pulley)
• The ballscrew mounts on the Y axis, and how they attach to the frame
• Lack of fasteners all-round

I would like to hear everyone's thoughts on the proposed machine. The build will be documented here soon, given that the design doesn't change dramatically as a result of this thread.