For this assignment we were tasked with cutting out two identical diamonds using the plasma cutter and applying post-processing methods we learned in class to our diamonds.

Before we can cut out our diamonds, we first need a .ai file that creates the paths needed for the plasma cutter to follow. Using the provided diamond template on canvas I then imported the recycle symbol from the noun project to create the shape I wanted to cut out.

Now that I had the shape I wanted to cut out, I proceeded to import my file to Torchmate to create a .dxf file that would create a path that would cut out two exact copies of my diamond. After doing a dry run to make sure the current path wouldn’t overlap with previous cut out diamonds, I then let the machine run with the cut function on.

For some reason one of my diamond’s path was set to cut out one of the inner shapes after cutting out the diamond which caused the symbol to be cut out improperly. I modified the file to cut out another copy which worked but was slightly smaller than my original successful cut.

Now that I had my two diamonds cut out, my next step was to remove the dross that was leftover from the plasma cutter. Using an angle grinder, I removed as much dross as possible to create a level surface on both of my pieces.

Although I wanted to remove some of the dross on the inner side of the symbols, I decided not to due to the low amount of metal remaining between some shapes. Luckily I was able to remove most of the dross with the angle grinder and made sure the surface was clear of dross.

My next step was to sand blast my pieces in preparation of my final step. I placed both of my pieces into the sand blaster and used the sand blaster gun to get an even texture on my pieces. Due to the lack of light inside the sand blaster it took me a few tries to completely cover both pieces with the even texture.

The last step I did for my assignment was powder coating. Originally I wanted to use green powder for my diamonds but it wasn’t ready to use so I decided to use blue powder instead. The process for powder coating is pretty simple but I had to be careful since there was a possibility of shocking myself and the dust posed a health risk if inhaled.

Before setting up the powder coating gun, I first used a rack from the powder coating oven to hang my pieces from and placed it between two sawhorses. I then connected the powder coating gun to a compressor and set it to provide 5-10 psi. Before I connected the powder coating gun to power I clamped the ground cable to my hanging metal piece. Now that everything was set up I just sprayed the powder onto my diamonds and applied an even coat on both sides. I then took the rack back to the oven and waited 5 minutes for the oven to preheat before placing the rack into the oven and letting the oven run at 400 degrees Fahrenheit for 20 minutes.

After letting them cool down for about 20 minutes I was able to handle my finished diamonds. One of the diamonds came out a bit darker than the other one but that was probably due to applying more dust to it. The shade of blue I ended up with was darker than the shade of the powder which was unexpected but fine with me. Overall I was really satisfied with how smooth and even the powder coat ended up, which really helps with making my diamonds look identical to each other.

Cost Analysis:

1/8″ sheet of steel from Amazon: $12

Assuming 2000 W usage for 3 minutes and electricity costs $0.113/KwHr : $11.30 to run plasma cutter

Assuming 500 W usage for 20 minutes and using previous electricity cost : $18.83 to run angle grinder

Assuming 350 W usage for 5 minutes and using previous electricity cost: $3.30 to run powder coating gun

Cost of Labor: $30/hour *2 hours = $60

Total Cost: $105.43