Accurate Strong Gantry

[vargai]

What size cutters are you planning to use in alu? 50mm face on plastic wont generate much force.

Welding is you are all probably aware is an art in its self and you must only weld small sections at a time and move around the frame to reduce heat build up. Its slow but the only way to go.

You can design to minimise joints and increase contact area so spot welding can be used.

Is your model in AutoCAD? If so I could help out with the frame design. Hopefully increase strength and reduce the weight! :0)

I have downloaded some kind of study about machining force and my
goal on 1000 N is not oversized requirement. I hope I can use max DIA 10-12 mm with moderate technology and dia 30-35 face mill on same way.
The machine will give the right answer and I will give a "reluctant" acceptance to it. I do not care if some work take a while since I will use this machine on one off and small batch production. With good strategy and preparation I even can compensate it but not bother if not. I have a day time job so it will be a free time profitable passion.
Regarding the design I am rather analyst type and it is important and challenge for me to see the theory behind the result.
Everything happens according to some kind of theorem and if one catches the rule then catches the physical result.
So thank you for your help in advance.I still have to adjust my plan a bit and revert it later.
I use Solidworks but the estimating the elastic deformation (strength ) would be a big help too.