Yet another exquisite post that is as informative as it is eloquently written. Hats off my brother, your posts are always appreciated.
Yes, I’ve given thought a time or 2 to something different than the router. However, as much noise as I make about wanting to have a proper lower-speed spindle, my work doesn’t merit me putting much serious thought into getting one. The router has served well for cutting plastics/composites and such, and I know it isn’t placing stresses on the Z axis that would be of concern regarding accuracy. Even if I had a spindle with a more appropriate RPM range for metal/steel, I have little faith that the Z axis could deliver an appropriate level of accuracy due to deflection. All that said, I think the Z axis is well designed and adequate for the target users that primarily cut wood at high RPM’s.
I’ve basically eliminated aluminum from my “menu” on Xometry, and only take the occasional parts that fit my profile. For example, I just took on a polycarbonate part that fits nicely on my machine (it’s on there now as we speak).
Yes, I do recall that. I’ve always been a fan of that type of spindle that is secured at the bottom and has good bearing support as well as hits the target of a lower RPM range. I’ve also been a fan of plain bearings which are better suited for heavier machining. Typical linear bearings don’t provide the surface-area contact that is critical to reduce vibration. I had started playing with a design to accommodate that type of spindle, starting with getting the Z axis stepper out of the way and driving it with a generous size timing pulley (as I had on my X-Carve). This would allow clearance for the spindle motor, but I would still require a new spindle carrier, which likely would not resemble the current one.
I loved that machine! However, concerns of how much room I’d end up with after our move as well as justification for the space it would require didn’t add up, so I sold it before the move with the assumption I would replace it at some point if after the move if I could justify it. In my current shop (shed), I really don’t have room to absorb it, nor do I really have much interest in machining steel. For the rare occasions when I need to machine steel, I can make do with the Onefinity. Case in point is when I modified my controller housing (steel box). I was able to cut the front controller cutout larger to accommodate the 8" monitor which was larger than my previous DDCS controller.