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Thanks John, I don't often get compliments like that... (I will try not to over-speak.)

The weight you will be able to handle will depend on your design...

Solid rail glides (linear slides)...

Those cables with foil are meant to be crimped with a shielded connection. Both the center (bare wire), and the shield should be connected at the crimp-connector.

Braided is better for durability,...

You should build a 1-foot square work area... The space it consumes will be expectedly twice that size. For engraving, you want to obtain the greatest precision as possible, which translates into...

Hmmm, who would have thought that you could re-patent a simple pulley, just by adding a wall for it to slide upon!

YouTube - Rolamite 1


You know where the CNC community uses this... In...

3.5 HP is roughly about 2,609.94955 watts, or 2.6 kW

That should slice through butter quite well...

(Just for those who were unsure where aluminum and soft-metal ball-screw setups are used......

Well, that is not a disagreement... Not in my eyes. LOL.

Like I said, if your holding power is adequate... If not abused... If not cheap...

You obviously have high quality ball-screws,...

You will also get more stable precision, through the entire Z-axis motion, having your Y-axis move up/down like that. The constant distance from the rigid structure is where you will gain that...

Ger21 is a CNC-goldmine... If it wasn't for his info, I would still be pondering how to turn my screws. (My first attempt wasn't bad, but his way resulted in much better results.)

Needing a CNC to...

To me, they look like Nema-17 form-factor motor, and your specs for the motors operating power suggest that you need more beef.

4.0v x 0.95a = 3.8w

3.8 watts = 0.005 hp
0.005 hp x 12 IPS screw...

Sorry, had to defend my knowledge... lol

Making one handle for example...
Tool-path = 5kW motors consumed (Holding power and traveling.)
Spindle-power = 10kW (90% wasted just spinning.)...

The purpose of the relay is to control the spindle, fans, exterior lighting, vacuum, etc...

The things that you don't want to keep turning on/off by hand, which may not need to be on all the time....

Can you post a photo of the problem area?

I suspect that there is a burr on your track, or a flattened/scuffed bearing on your glide system... Possibly, also an issue with too wide a span with...

Have you done a break-in on the chain yet? (Run the full length like 1000+ times, fast and slow, on all axis. Tighten slack and re-grease it, and then run again, etc...)

If you do not have...

I am curious how you are getting 10 micro-steps?

You would need 5-coil stages to get that from the controllers I know of.

Normally, there are 4-coil stages, and thus four wires, two paired sets...

The only discount you are saving, in mass production on any single-spindle CNC is on the material being milled, if waste is not large. If 20 fit onto one piece of milling material, that is your...

MDF is not a great choice for long-term use, however, it is a great "first machine" material. Expansion is limited by painting the material with enamel-based spray-paints. The only critical expansion...

Coasting without power is safer than holding position, while it pins-down your hand, and needs to be programmed back-out. Without power, unless you have a mammoth-machine... there is little threat of...

Although LPT/PP are a dieing trend... There is still support for them, VIA PCI cards and even external cards. POS and many corperate old computer printers still depend on LPT/PP. (Though, the...

That is similar to how I did mine, except the only stone I have is on my grinding wheel. That is what I had in mind for my jig, except the jig would be on a pivot, with a long handle and a stop-screw...

Another update...

I got my three drive-screws. Decided to get 1/2" 13-TPI all-thread, just so I had enough room to turn-down the ends for the 7-mm ID 608zz axle bearings, and the 10-mm ID needle...

If needed, for better safety, though not required...

An electronic break which "releases" whenever power is applied, will help reduce the router free-spinning. (Again, it is not needed.) This...

For linear setups, you have...
Classic mounted roller bearings on a flat-track or angle-track. (Common DIY use)
"V" bearings on an edge-track, or bar, or square-tube. (Alternative to normal...

This is the video series I found, which got me started in my project. Much of the information I knew, but again, much I did not.

Watch all his video's and visit his links.
YouTube - Step...

Almost any type of switch will work, depending how you setup the contact point. The voltages/amps are low, and you will not be hitting them over 10,000 times under normal situations...

The only...

While shopping for the drivers and break-out board, or combo-setup, and motors... keep my suggestions in mind, even if the values are not what you are looking for.

A 24v @ 3a motor has the same...

I think only the G540 has the built-in controller (No external break-out board, as it is inside the case.)

However, it has enough inputs for most table switches... You only need one input, at the...

Remember, the purpose of an "emergency stop" is to kill power directly at the source. (As opposed to being an input to a digital readout, requiring the computer to act on that action. That is...

I have that same controller board and similar motors, by the specs of the nema-17 kit, except my motors are nema-23 form. (They have more torque and are super-quiet. Mini-stepper brand, I believe...

Birch-plywood is a good alternative to MDF, if it is thick enough. However, it may not be as "true" on the flat-surface. (Plywood tends to have un-uniform surface, due to multiple layers of glue and...

80/20 is actually 6105-T5 aluminum. (It should be.)
Misumiusa uses (A6N01SS-T5 Special class HFS) and (JIS-A6061SS−T6 GFS)
Do not fall for the "gimic" of 8-series, which is just an internal...