It's down to the stiffness of the collets. For any given type of ER collets (eg. ER32), a collet at the large end of the size range (say 19mm - 20mm)...
Not sure what the colloidal means - here's the stuff: http://www.westsystem.com/ss/406-colloidal-silica It's extremely fine, light and fluffy. I used...
I'm going with the casting route instead of 'machine for solid' because there'll be so much waste. The total thickness of the outside frames has now...