1.AI file Design

I had sketched a Victini before the machine was broken, but I noticed that plasma cut will not be as precise as water jet , so I gave up my first design.

Again, I designed a brawl stars logo in November.

The hardest part in designing is to evaluate the kerf of the plasma cut to ensure every piece cut is as expected.

2.Plasma Cut

It was the most struggling part for me. We need to be well-prepared before entering the metal lab. The first time I tried to use the machine, it didn’t work because the computer was not fully connected to the equipment. I made a trial cut, but the plasma power became too big so there was liquid splashing out. I stoped the machine at once.

The second time I go to the metal lab, the power engine was not connected to the air pump so I asked a lab assistant for help. This time I set the electric current into half. I followed the steps on the booklet, set depth to 1/8 inch, male and climbing cut. Connecting the software with the machine and choosing the proper 0 position, I made a first successful cut. The sound of the plasma was so annoying.

However, the second piece was not that wonderful as one part at the angle is not fully cut, so I decide to take this piece as a test for post-processing. The third piece even disappeared from the water surface because there was no support under the position where I cut it.

After I found out the reasons, I successfully made my fourth piece.

3. Grinding

Since I cut the steel pieces, I could use the magnet to fix my diamonds. It is important to wear the goggles and the apron. There are many skills of grinding, like how the force should be applied and how the angle between the metal and grinder should be.

It was a tiring process for my hands and backbone. After Eliminating all the ugly edges, I found out the gloss was attractive to me.

4.Sanding

I tried one diamond with the sand blaster in the wet lab, but I don’t like its texture, so I ground it again. Hence, I decided to only sand the edges by the files.

5. Vinyl Cut the Stickers

Because the logo has two colors, I need to ensure that each color is separately sprayed. using the AI document shown above, I cut for vinyl stickers. The area of the sticker should be proper, which costed me a little bit of time.

6. Spray Paint

It was the most exciting part. I put on half of the stickers, sprayed the diamond black, and waited for several hours; then another half was sprayed yellow as I teared off the the old stickers and covered the region already colored with sticker. I found that the edges are in two different color due to my spray, so I spray paint the backside with orange.

workspace after I sand the diamonds

COST ESTIMATION

Material(all found in Amazon):
1/8”Steel plate: $23*0.3=$6.9
spray paint: $11*3*0.05=$1.65

Labor:
$30/h (Houston average wage)
$30*6=$180

Machine:
Plasma cut $50/day (https://www.unitedrentals.com/marketplace/equipment/welding-supplies/welder-accessories/plasma-cutters)
Angle Grinder: $30

Total:$238.55