In this project, I tried my hand at crafting a metal piece with the letter “C” using a plasma cutter.

I started by designing my “C” using a diamond template, using Adobe Illustrator as the tool.

Setting up the plasma cutter took a few steps. I turned on the equipment, checked for green lights, and connected to the Signal Generator. A line test helped me find the correct settings for cutting.

Then came creating the tool path. Although I met some problems when creating it due to my first version of the dxf file of diamond, I finally figured it out. I used software called Torchmate.EDU to import my design and make a tool path. After that, I switched to Torchmate 4 to set the feed rate and prepare for cutting.

Next, I did some post-processing. Since I cut it with steel, I used an angle grinder to smooth it out. After that, I thoroughly cleaned it with a sandblaster.

At last, the surface of the metal is really smooth. When writing the blog, I found myself missing the last step of coating the metal; I also forgot to take a photo of my final piece, but I will add one later.

Estimated cost:

Steel sheet: about $0.5

Labor cost: 5hr * $15/hr = $75

Machine cost: 0.5hr * $50/hr = $25

Overall cost: $100.5