Re: pic: 6 inch wheel design
 

You can mill with that? Impressed, I would have thought it would dull. even still the 3 axis cnc issue remains. If you send it to a sponser to be made, you may as well just buy it.

Re: pic: 6 inch wheel design
 

I have heard (though never tried) that you can mill on a router table with an all carbide bit. I don't see why something like this wouldn't work here. Obviously a router table won't help, but you can still use the bit.

Re: pic: 6 inch wheel design
 

Ball-end mills are neither expensive nor rare. We have a set.
Yes indeedy, but it's probably more dangerous that I'd be willing to let a kid do. You must use a template for the router to follow, there's little chance of really controlling it freehand. We cut the triangles into the 3/16" aluminum we used in our rookie year for our robot cart (the pattern matched the .090 'armor' on the robot). An experienced parent did that for us. Me, I thought he was crazy, but dang if he didn't do it nice and neat.


As for the wheel, I'd probably turn it on a lathe before I brought it to the mill.

Re: pic: 6 inch wheel design
 

On a router table?

I'd also lathe out as much of the piece as you can initially before milling it out.