I've got a couple of questions along these lines. Assuming I'm getting parts cut from thinner stuff (say 1/8" to 1/16", so kerf angle doesn't bug me), what's the smallest cross-section part you'd recommend making?
Take the pterodactyl example off the web page... That same kind of keyed construction technique would work for bot frames as well, especially if the joints are backed up with CA or epoxy. But it'd be nice to spider parts out as much as possible to save weight.
Soooo... I was kinda thinking of a square cross-section for the spidered out bits and pieces:
I'm not asking so much from a material strength standpoint. I know that's up to me to calculate and make sure I stay within bounds. I'm asking more from a machine setup standpoint. How thin and light can I go and not risk distortion, shifting, etc.?