TL:DR – if you need machined features, make the part a rectangular prism.
All about Axle Blocks:
In 2.810, many teams choose to make lots of parts out of waterjet aluminum plate, and then post machine those plates. This is a pretty intuitive strategy, but isn’t the fastest. I created a couple sample parts and then filmed myself doing a time study for how long each one took.
The waterjet is still an amazing tool with great capabilities, but if you’re going to do any post machining (except maybe tapping waterjet holes), you’re better off machining the whole part.
Paul Carson Designs 