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If your Z axis has "fixed rails" (attached to gantry carriage) and cars move (attached to Z plate) up/down, then you don't have any stiffness penalty for increasing Z travel up to allow for tool...

Bolting a manual mill to it?

Just build a steel bench

Or maybe regular concrete. Do not waste money on specialist grout or EG.

The base will not contribute strength/stiffness to an existing...

Did it make the sound from new? Have you tried altering the tuning at all?

BK mounts are only about 100N/um stiffness

Larger ball screws do have higher axial rigidity

Longer and double ball nuts have higher axial rigidity

Craig there are no physical signs of rolling. They do not have the little grooves in the crest (major diameter) that rolled screws do.

Are they the same standard as a premium brand name? Probably...

Craig you are incorrect

TBI make ground ball screws, as well as rolled (like every manufacturer). Loon at their catalog.

I have three ground TBI ball screws in my shed.
The difference between...

v102: Are you replacing the servo motor only (trying to use an existing drive) or are you replacing servo motor and drive together?

Craig, you are going to have to buy Delta B3 or E3 in the future. Apparently E3 is replacing B2

2 metres per second = 120 metres per minute = very fast

20g is massive acceleration

Your frame is completely unrealistic for what you want

Buy the ready made cables!

Usually:
Step pulse, ideally differential, therefore 2 wires
Direction pulse, ideally differential, therefore 2 wires
24v or 0v (depending on preference/wiring)...

Is the motion fixed / always the same? Or will you change programs?

Could do with an arduino / microcontroller (or multiple) if you don't need to change the program. Also possible to change...

Yes you should buy from a store that specialises in that type of product.

Fred / BST Automation is great for linear rails and ball screws.

Always check how bolts will work

You will likely want flanged linear rail cars - they can be bolted from below

You need to provide a picture / model.

It sounds like you are asking about 2 rails on each side? 4 rails for one axis? It is very rare that more than 2 rails per axis is beneficial

HGR is...

BST Automation on aliexpress
Fred is very reliable
Has been a seller since 2011

Max feed rate 500mm/sec
Screw length 500mm
Acceleration time 5 sec

You will never get close to max feed with that acceleration time

Acceleration is a major determinant of torque required
...

Why worry so much about air? That small amount of air should reduce modulus by only a small amount.

You get a much bigger stiffness increase by increasing section size by a little bit. 10%...

If multiple tool holders have similar marks, the spindle taper is damaged.
Probably had chips jammed in.

Often fixable with some work.

A ding / scratch in metal will usually result in a...

I have personal experience of epoxy creeping when used under linear rails / ball screw mounts. I don't have a measurement, but there was a visual impression / outline in the epoxy.

I would not use...

From my understanding the 900kg is a vertical load on top of the plate with a rolling element (caster wheel) between the moving plate and the load.

I.e. the 900kg load is fixed horizontally, and...

https://www.igus.com/info/energy-chains-select-bend-radius-cable-carrier-ca

https://dynatect.com/resources/how-to-size-your-cable-carrier/

Bend radius may be the centre of the drag chain (not...

32mm is overkill for 300mm travel

You can use a much smaller screw, such as 16mm, which will require much less torque to spin.

From my understanding of your description:
You are moving a plate...

My limited understanding was that vector mode's main advantage is better low speed torque, and slightly tighter speed regulation (which doesn't really matter at higher speeds usually)

I have practical experience of what Peter is saying about epoxy levelling.

Even with super slow hardener, epoxy did not self level unless 5-6mm deep.

Epoxy is soft. Over time it has crept -...

Servo would be a better choice

Stepper plus gearbox (to increase resolution) will be poor for high speed

Where did you get the settings from?

15mm/minute feed rate is very slow. Feed too slow = rubbing = heating and dull tool

What brand rails and what preload?

Some rails are meant for rapid travel and loose positioning - they have no preload and have a bit of play when force applied.

What is this for?
What is a 'spacer'?
Why does it need orings in the end?
How precisely do the orings need to be aligned in relation to 1. the spacer and 2. each other?

Agreed

$2000 will not get a machine you can use for aluminium with good tolerances, or any decent machining speed

Anyone claiming to make 500k a year with a machine that cost 5k is BS. Let me...