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I cut aluminum a lot. You have to have right alloy 5052 or 6061. 3003 Is to soft. I am using .25 single flute endmill . I can cut at 110 ipm with cold air gun. Depend on the size of final product I will cut in two or one pass. If something small I do last pass of .040. Maximum pass of .125...
like this http://www.zoro.com/graco-handheld-paint-sprayer-32-oz-72-gph-16n657/i/G5184435/
I got one works from 120v. It is good for a painting monuments on site. But it is only rated for 55gal of paint. Ifter that you have to rebuild a pump.
I you would ask my opinion. I would loose raised border. Make it 45 bevel. Main letters .75-1 inch PVC small letters painted or vcarved in.
Making frame flat will add more dimension to the letters.
If you don't care about wood. Make frame out of PVC. Wood grain easy to make and you can use...
How big is the table? Long ballscrews are expansive . I would go with rack and pinion. what kind of rails? Nema 23 usually has 1/4 shaft. You better of with nema 34.
Are you zeroed from a table or from top of the material.
if table probe your spoil board.
if top of the material measure you material.
Check for a backlash on Z axis.
I been cutting aluminum on my cnc all the time anything from .040 up to .25. If you look at chip load for aluminium you will be cutting at 12000-24000rpm 60-150 ipm with .25 single flute bit. Even cnc with aluminum gantry will do it mine is 6x8 .1875 <100lb gantry with r&p. Heavier base router...
My advice is to start small unless you have committed contracts.
Contact you local sign suppler and ask there sales person to stop by and talk to you. Do your homework on the subject before, so you do not look like an idiot.
Subscribe or buy some sign making and printing magazines and read...
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