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Raspberry PI4 test version of the project is now online in the test branch (with docs how to connect), if you are interested try it, more info on the discord channel.

github.com/atrex66/stepper-ninja/tree/test

discord.gg/tKBEQGqw

In the meantime, I’ve slowly started building the prototype.
I’ve decided to go with LinuxCNC in combination with the Mesa 7i96s and the THCAD-2.
All parts were initially 3D printed in ASA-CF.
In practice, it will have to be determined whether this material is strong and rigid enough.
If not, the parts will be replaced. For now, I want to test the concept first.
The axes are driven by 3Nm Nema 23 stepper motors and an HTD-5M timing belt with a 15-tooth pulley, without any gear reduction.
The frame will be made of stainless steel square tubing, 50x50x3 mm.

I’ve just started working on that.

Any tips or feedback are very welcome! I'm here to learn  

It's a question that I've been asking myself for quite a while. Linear interpolation is quite limited in its accuracy as well as its ability to maintain constant velocity. Have there been any attempts to replace that with higher order polynomials / b-splines / NURBS etc? I saw the recent great achievement to implement s-curve acceleration (add a setting for jerk), but here I'm thinking more about directly improving the motion planner. I understand that this is significantly more resource intensive, but honestly, for a modern PC it should be trivial to compute.

I am still working on the servo load bars. In Dmitry's axis config for his VTC20, he has net trq5 nyx.0.servo-05.trq-fb => pyvcp.trq5 in nyx-6-pgui.hal (servo 05 is spindle in our VTC setups) so I was going to try to work with that. I just haven't tracked down nyx.0.servo-05.trq-fb yet to see if its a preconfigured input or if it has to be created.

Somehow i just lust my long winded reply to your suggestion...
short form: I would be happy to find some form of documentation to get that sserial port config done. .9serial and hostmot2 documentation don´t help me at all unforuntately

"sserial_port_0=0000000F" should open up channel 0-2 for 7i77 in mode 0 and 3 for 7i84U in Mode 0

no sserial device answers to

"show param hm2_5i25.0.sserial.port-0.device-count"

i am pretty much out of my depth setting up that smart serial connection