Hello-

I'm building a CNC router (based on the Solsylva design). I was wondering what I would need to do to create a machine capable of cutting aluminum. The specific project I have in mind involves cutting irregular-shaped holes in a 1" piece of 5052 aluminum plate.

Regards-
Eric

Ideally, you'd want a machine far more heavy and rigid than one made of wood, and with "real" linear bearings instead of rollerblade bearings, and the ability to use flood coolant. Having said that, you may be able to do what you want by taking very light passes. Just be sure to keep the chips clear, so you're not re-cutting them.

Just to add to Gerry's list....ballscrews, linear rails of size 25 (2 trucks per rail), servos, rigid spindle (minimum would be something like the R8 mini-mill spindle that most of us have modified), etc.

If you have a small cut envelope, you might be better off getting one of the larger bench-top mill drills and CNCing it.