I've always been fascinated with automatic manufacturing and have been avidly following the homebrew 3D printing for many years. I've always been daunted by the ~$1,000-2,000 cost of getting into the space, along with not having anywhere to work on such a thing. (I have five kids and until recently a very small house.)
Last summer, we expanded our home and for the first time in many years I had access to a proper garage. I therefore began a project to build a CNC router. I had considered additive processes (3d printing) and subtractive processes (machining/milling) and was conflicted for quite a while as to which would be a better place to start. After extensively reviewing the different options out there I settled on an MDF framed, router based mill as being affordable and buildable with the tools I had at my disposal.
My goals with this project have been to boostrap from highly inaccurate hand tools (power drills, a tiny cheap table saw, wrenches and the like) to a device that lets me cut with < 1mm accuracy in materials up to the hardness of aluminium.
Another option is to first make mock-up components in either foamboard or cardboard and duct/masking tape.
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