sorry for late reply, but i have been crazy busy. my ; progress is slow. I have redesigned most parts for increased motor size. I have designed many of the molds. I will be injection molding with HDPE. ;
I fear the PLA/ABS printed materials may not be strong enough for a NEMA34 version. I am looking at staying away from metal as much as i can, unless its standard easily obtainable shapes like thin wall tubing. Looking more into using epoxies and using CNC router to make molds. I’m making notes for Thor XL as I build the Thor. I have a FormLabs Form 2 printer on the way, as well as my heavily modified MakerBot replicator 2 (Aluminum Gantry parts, and bed supports, Heated build plate from a 2X, increased build area 6cm in z axis, and made top and sides to hold temperature inside).