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CNC Plasma Cutter

The PlasmaCam System is the most versatile CNC Plasma cutting system , What you can do and create with this
machine is limited to your imagination... The uses I've found for this machine just keeps adding up! If you browse through my
different projects you will notice that I use this system to make some, if not all, parts for that particular project. I have even attached a
rotary cutting tool to this machine to cut some plastic parts out of ABS Plastic.

So far this is what I have used it for... and more!
Tools I have fabricated...
Ornamental Metal...
Prototyping parts...
Production run of flat parts...
Custom PC Cases...


 
CNC Plasma Cutting Machine by PlasmaCam, this thing can cut with speeds of upto 1000 ipm!!

   
 I have 2 plasma cutters, the HyperTherm 380 and the HyperTherm 1000.


 Below are some other Tools that I had designed and fabricated using the PlasmaCam system...
If you are interested in making any of these tools yourself (Cheaper than buying them!)  I have DXF files available so you can cut them out yourself
if you own a CNC Laser/Plasma cutter, or If you are interested in parts let me know....
Ornamental Scroll Bender.... I had cut multiple pieces of flat 3/16" AR Plate and  welded them together to form the 2 parts of the tool... The top part of the scroll bender pivots out so the material can be inserted and bent with out having to reposition your part.
   
 
Below is a pic of some 1" x 1/8" HR Flat Stock I used the scroll bender on....

Compact Steel / Tubing Bender... I had designed and cut all the flat stock out of 3/8" thick HR sheet steel with the PlasmaCam System, then I machined all the holes on the Mill and machined all other parts and the tooling dies, the tooling dies were then heat treated.  The pins I used were some hardened steel dowels pins with a shear force of 120,000 Lbs+. I also fabricated a Picket Twister for this tool, I just have to finish the handle for it. And I will also be fabricating a basket attachment for it also.
  
I used the PlasmaCam software to place all my holes, I exported it do a dxf file and printed it out to scale and transfered it to the parts. The holes did not turn out too bad considering that my mill does not have a readout for the x and Y axis, all holes had to be lined up the old fashioned way, slow and patiently! The pins fit snuggly into the holes and slip out quite easily when I need to replace dies or reposition the tooling.
  
The Handle, shown below left, was also cut on the PlasmaCam System, then the holes were milled. The Base mounts were cut out and welded to some 2" Square x 1/8" Thk tubing. I have 2 mounts for the bender, a bench mount and a floor mount.
  
Now all I need are some dies to do round tubing, anyone have a spare set of dies for bending 1/2" to 1" hollow tubing with a 3" to 4" bend radius (6 to 8" diameter)?Let me know and I will be glad to take them off your hands, it will save me some time from having to fabricate them myself. (Maybe there's something I can trade you for them....)

A compact bench mount Stell Ring Roller.... As with the above bender, all flat stock was designed and cut out with the PlasmaCam system.... all other parts were either milled or turned on the lathe. the pics below do not show the main 3" roller die installed, but you can see it sitting on the table next to the ring roller. At this time, I still needed to bore it out to 1" and weld the set screw collars onto it. I had designed this tool to use interchangeable dies for differrent profiles of material. The handle grip is made out of delrin with a knurled finish, the handle crank is cast iron, salvaged from a Hobart Meat Packing machine, the bearings were also salvaged from the same machine.
The 2 bottom dies are raised into the knurled top die by a mini bottle  jack, both bottom dies and top die are supported by
flange mounted 1" bearings. I was going to use a Hydraulic jack, but this is all I had on hand.
 I will be replacing it with a suitable mini hydraulic bottle jack when I get my hands on one (easier to pump than twist!).
This ring roller is very compact, it is only 13 1/2 " tall, it's capabilities include, upto 1/4" x 2" HR flat stock,
1/2" Square or round solid HR Steel, upto 1" Square 1/8" thk. tubing, 1" x 1" x 1/8" HR Angle, etc. Once I get some more material to make more dies it will also be able to bend hollow round tubing, upto 1" in diameter.

 
07/16/07 - Added some 2" Diameter 6/6 Nylon to be able to roll smaller rings with smaller diameter stock.
You can also see the roller die installed now with the set screw collars welded on. You can see the 6" ring I rolled with it out of 1"x1/8" flat HR stock sitting behind the roller on the table in the backround.
 


  Some sample ornamental pieces that I cut on the PlasmaCam....

Above design was cut out of 16 Gauge Galvanized sheet steel on the PlasmaCam Machine... (size is 14" Dia.)

   
   

 

 Below are some of the machinery that I had prototyped using the PlasmaCam System... and some of the production parts I cut on this system for Kansmacker the company I work for full time...
   
   

 Some production parts....
Above middle and the right photo are preformed steel, I made a jig for cutting the slots on the 2"x2"x1/8" angle iron,
 and for cutting out the arc in the 2"x1"x1/8" Bar channel.

 Some custom PC cases I fabricated using this system...
Case  Cover #1 (Aluminum):
This was a case cover for one of my Shuttle XPC's...
Case # 2 (16 Ga Sheet Steel)

This was a PC I put together for my truck originally, but then I ended up building the Touch Screen Armrest console to house the PC into instead.
Case # 3 (18 Gauge Sheet Steel)

The top cover design was cutout, then I glued a piece of red  plexiglass behind it, the plexiglass is backlight by the lighting that I used for backlighting the text that is cut out on both sides of the case.

   The materials I cut on this machine range from 11 Gauge Sheet metal, all the way to 3/4" HR sheet steel.

The combination of the machine capabilities and the ease of use of the PlasmaCam software,
 I am able to easily make changes or alter a current part before cutting.
 Once the prototypes are done, I can export the file to DXF format and send them to our parts manufacturers for production.
Since we have purchased this machine, our prototyping costs have gone down dramatically, and the machine pretty much paid for itself
within a few months! This machine is by far the best and most complete CNC Plasma cutting system I have ever seen or used.



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