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I did watch some youtube video about "cheap" aluminium cutting (carbide mills), it is far from easy.

It seems plasma/high energy laser cutters are a must.




Plasma cutting aluminum has challenges all its own.

Hydrogen production for one (you can imagine where that's going :) ), and you'll need some shield gas to make it work reliably. Cutting speed is going to be pretty impressive, edge quality not so much compared to a laser.


Then we are back to high energy laser CNC cutter...


Yes, for sheet that is the best way. For complex shape it's milling for subtractive and sintering for additive.

https://www.btu.com/applications/sintered-metals/




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