[sanddrag]

On plasma vs. laser, I own a small 30W laser and we're looking at getting a higher powered laser and also a plasma. As Don mentioned, a plasma has no problem cutting aluminum plate, but it may require some finishing work, and does need an industrial "shop" type environment to operate. A plasma can be had for around $10,000. Lasers are nice and precise and clean, but I have not seen one that can cut aluminum for under $50,000. If it is out there, I sure would like to know about it. The smaller lasers can be operated in a more office/classroom type environment, with an air filtration unit.

A small laser is useful for cutting plastics and plywood, but not metal. 1/8" Delrin is about the max on our 30W. We use it for mini-sumo robot projects and things like encoder mounts, but not too many other FRC robot parts.

Boss Laser makes some relatively affordable machines that will cut up to 20ga steel quite nicely, but I can't find the application for steel sheet in FRC.

On your indicated budget, you're looking at a small imported lathe, a small imported mill or larger used mill, and a modest amount of tooling and workholding.

Also, don't understimate the value of a nice toolbox. The Harbor Freight industrial glossy red ones are the best out there for the money. You can put a small lathe on top of the 44" 13-drawer one.