I'm still in the design stages and ordering raw materials for the basic machine. This is my second build with the first being a modified version of the one Chris Fitch built for his Woodsmith article a few years back. The machine has done really well for what it is, and will be making some parts for this new design. It will be a hybrid of Baltic Birch plywood laminate structure and aluminum hard attach points and bolt plates. I am planning on pour in place rigid urethane foam for the base legs, gantry beam and columns, and possibly the table torsion box too.
The gantry carriage and Z axis will be fabricated from aluminum. Using 25mm rails on all axis, and X and Y being driven with Avid's Rack and Pinion drive system. Ball screw drive on the Z axis. A lot of details to still get through on the design but it is coming along. Cutting area is about 77" x 68" with the rotary axis being in the 77" length. The rotary axis is dropped and will have a 12" swing x 48"ish length.
Here are some screen shots from the CAD model.