CNC Plasma Cutter
Sheet metal fabrication offers a versatile approach to creating strong and lightweight structures, whether as the framework for complex projects or as standalone tools for organization. Plasma cutters are particularly attractive for their low barrier to entry and compatibility with a wide range of materials. When paired with forming and stamping, the possibilities expand significantly, making plasma cutting an excellent choice for fabricating both functional and artistic designs.
Project Definition
The table needed to handle materials between 16 gauge and 1/4-inch thickness, primarily in steel and aluminum. Safety and portability were key considerations, as the table’s capacity would influence its size and footprint in my workshop. Additionally, it had to include a bend line plotting capability, enabling the creation of complex 3D structures from 2D sheets. This functionality would expand the table’s versatility for a wide range of applications.
Project Design
The design was inspired by a popular online template from JD’s Garage. I customized the frame for a 2x4-foot envelope, incorporating a dual-sided gantry to support the plasma torch and improve stability. Many components, including motor mounts, bearing housings, and the torch housing, were 3D printed for rapid prototyping, with plans to replace them with metal parts later if necessary. I opted for 24V controls and compact stepper motors for precise, low-speed operation. A water table was integrated to mitigate hazards from sparks and dross. To further enhance the system, I added a pen plotter for marking bend lines, designed to be spring-loaded and mechanically actuated to maintain contact even on warped sheets.
Project Delivery
Despite being built on a budget with a partially 3D printed frame, the plasma table exceeded expectations. Through several iterations, the addition of the spring-loaded pen plotter enabled precise and consistent bend line plotting. A custom CAM programming template was developed to streamline the process, allowing for quick generation of cutting paths and bend lines from a single software suite. This system ensures precise alignment of bends, enabling the fabrication of complex shapes with multiple bends that fit together seamlessly. The final table is a compact, portable solution that delivers professional-grade results while remaining accessible and adaptable for future upgrades.
