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True enough. If you're not too invested in Mach3 you should try out EMC2. I know for a fact that 6-axis wire EDM's have been successfully built with EMC2 as the controller.

Secondarily, the HAL...

Nice sonic screwdriver ;)

Currently searching for a picture or diagram on the intertubes, will attach it at the bottom if I find one. Systems like this are much better described in pictures or...

[Short answer: no. Read on if you've got some time to waste ;) ]

Aye, there's the rub. To make a recommendation would require more information. Minimum cross section, moment of inertia, strict...

No real idea, but I can throw a guess or two your way. It's an 'aircraft' part (or at least aircraft associated) so if it isn't 6061, it's 2000 series or 7000 series. 7000 series have a higher UTS...

So I take it from your description that you're looking to cut spur gears; much else would be a bit of a PITA without a 5-axis :o. If that's the case, there is a gear generator at Woodgears.ca that...

Are you working with Y14.5? If so, what exactly are you looking for?

General training materials tend to be quite expensive (Heck, a PDF of just the standard is over $150US), but if you just...