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There are several good slicer programs out there. Fusion will do it, but if you do not have fusion I would use either Cura or Slic3r. PrusaSlicer is a derivation of Slic3r and is also very good. As to the original issue, the slicing programs work in millimeters so if you export in inches you...

You can print some pretty fine threads on a Prusa, but I would not necessarily depend on them for strength. The robotics team I run uses 3d printers to make a number of items that are used on our competition robots. If we are doing just a fitment test we will print the threads in as we will...

I use Onshape pretty heavily with the high school robotics team I teach. It is powerful parametric modelling package. They have good tutorials that walk you through the steps of creating sketches, 3d models, and 3d assemblies. The tutorials also show you how to make drawings and bills of...

Thanks for the suggestion on the chuck key interlock. I teach kids to run lathes and mills so having one more method to keep them safe is always appreciated.

Press fit. We use motors all the time like that in FIRST Robotics Competitions. The pics look like what we would call a 775 motor. Just note that the 775 is a motor size spec and not a power/speed rating. We have 775s that range from around 5500 rpm all the way up to 18500 rpm. Power ratings...

I mentor a high school robotics team. FIRST Robotics Competition level. We use Fusion 360 to produce our gcode for our tormach 770. I would recommend it.

Square hole collet would be best if you have it. Quick and repeatable.