With the recent Masso announcement, and my work with FreeCAD, I am looking at LinuxCNC as an alternative to the Masso. (LinuxCNC seems to be FreeCAD’s baseline controller)
Being Open Source LinuxCNC (GPL2) are obviously free to use even commercially. And they seem to have a release cycle of every 6 months. Their GitHub appears active.
LinuxCNC has supported “cutter compensation” for years.
3 pole contactor (~$35, controls power to the steppers for safety)
Total was ~$500 for the important components. Add on some extra for estop switches, buttons, molex connectors, wire, an enclosure etc. You might need crimpers and other electrical tools if you don’t have them already. I use X11 forwarding to connect to linuxcnc from my laptop, so I never added a screen to the controller. I thought it was a pretty fun project, and I really like the final result. The build took me about two weeks working in the evenings.
Someone posted that the new redline controller has ethernet. That would be a better fix if true. Will keep researching before making a move. Also looking at LinuxCNC GUI options.