When I first viewed this project, I thought the hardest part would be deciding what image I wanted to incorporate into my diamond. Plain and simple, I was wrong. Although I had many learning moments in the process that had me confused at first, it was a very fun project that expanded my horizon on what I can complete that will possibly look professional like (if I had more experience, haha). It would be hard to imagine this project being done at home because I can’t imagine anyone having their own at home plasma cutter, but it could happen.

Step 1: Decide on my design

I actually spent so much more time doing this than I thought I would since I first had no idea what I was going to image on my diamond, then the image did not look correct when my diamond got cut, and finally I made my executive decision. I first wanted an owl and Cross on my diamond because those are two important symbols to me, but when I went to cut out my diamond, I forgot to realize that I had it at a diagonal on the TorchMaster application on the plasma cutter and got a height of 6 inches instead of the actual 5 inches in height the diamond needs to be. Therefore, I ended up with a diamond of a larger dimension (which is what not to do in the homework), but I genuinely contemplated on keeping it because it looked so good. So, I had hope that it would still look similar if I scaled it down to the correct size and it was tragic. The owl did not look like an owl anymore and now it was a blob. Therefore, I modified my design which consisted of removing the owl and centering the Cross better. I’m pretty happy about it now and I have some ideas for the 3 bigger diamonds I cut out:)

 

Step 2: Cut my file on the plasma cutter (and learn about the machine and its ins and outs this way)

Earlier, I talked about my troubles with the diamond size and my design, but oh there was so much more than that. When Mia and I first hopped on the plasma cutter to cut for the first time, we did not realize that the design on the computer was absolutely HUGE. After we set the path for it to run, made it a male cut, jogged it to the correct place, and then prepared for it to make a dry run, that machine went flying into the direction of the railing because it was trying to get to the beginning of the path for the shape. What we and the Lab Assistants on shift did not realize when Fault Signal Error 2 popped up that only the magnets were unaligned from the beam shift and that we just needed to pop it off and put it back on so it was perfectly parallel to the bed. Luckily, another person from the class under the problem and proceeded to be able to help. Other than that, it was very fun to position (I know, weird, but it reminds me of a puzzle) the diamond and jog the beam to the correct spots for the center of origin where it will start. With this being said, I managed to cut 4 good diamonds of the new solo Cross emblem.

 

 

 

 

 

 

 

Step 3: Angle grind the insecurities away!

After being so cautious with it during the learning session, I just got right into it with Emily and decided to get all the grit and slag off the sides (because it was looking rough on the back). It was very fun to be able to see the transformation from a ragged looking piece of metal to something in which I can rub across the entire piece and not feel anything protruding from it. See pictures to view my joy:)

 

 

 

 

 

 

 

Step 4: File the inside of my Cross

I wanted to incorporate another post processing method into my project, so I figured that I would metal file the middle of the Cross and try and get any slag that was in those small crevices off. The only file I could find was the more square shaped one, but it was perfectly sized to fit in the middle of my Cross.

Step 5: Sand the diamond to prepare for post processing of spray painting

I sanded my diamond with 4 different grits to try and dispose of any loose particles on it that can prevent a smooth time spray painting along with trying to prevent as sharp points as I can. I started with 60 grits, went to 120 grits, then 220 grits, and finally made a huge jump to 800 grits just to try and gain a smoother surface to gain a clean surface along with decently smoother sides sides than before.  I wish I had done a better job of trying to get the surface smoother, though, because when I spray painted one of my extra pieces without doing anything else to it, it had a lot of bumps.

Step 6: Be told interesting news and have to go a different way (sand blaster not working)

After I sanded, I was told interesting news concerning the sand blaster and how it would need a part to be shipped in to the OEDK. Therefore, I decided to ask for help from Joe to see what options are available to me that can help me complete my project. Some options included powder coating or spray painting on the diamond after it has been sanded. After also talking to Danny and Grant, I settled on sanding the diamond to try and gain a smooth surface and then utilizing Primer Filler to fill in any crevices necessary for a smooth spray paint coating. In between my Filler Primer coats, I would sand with 800 grits. However, I butchered one side on one of my diamonds because I pressed down too hard on it and it might not have been dried enough creating quite a bigger crater than I would have wanted. I wish I had waited more time for it to dry to handle rather for it to to dry to touch. After that, I was much lighter in my sanding. In a couple of places, such as the area I messed up on, I used 400 grits to try and really get the diamond leveled and then 800 grits to get it smooth again. I continued to repeat this process around 5 times on both sides of the diamonds until I became happy with the result (or got tired of the process…) and then I started to spray paint.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Step 7: Spray paint!

I would love to say that I chose my spray paint based on the quality and drying duration the can told me, but in reality, it was one of the spray cans left that I thought I would have liked. I began with one coat just to see what it would look like after drying for 5 minutes and then I sprayed on another coat, waited another 5 minutes to ensure that I would enjoy the double layer more, and then let it dry for ~50 minutes. I repeated the exact same process on the other side for both diamonds to try and gain the same result. Spray painting is one of my downfalls, so I just tried my best, but I have very shaky hands that have a tendency to continue to tremor even when I try and still them. Therefore, I am a bit saddened to say that I expected the result I actually got from my paint job.

 

 

 

 

 

 

 

Step 8: Model, baby, model!

My knight in shining armor! It’s done! Here is my metallic masterpiece in all its glory. Watch it sparkle, baby!

 

 

 

 

 

 

 

Step 9: The contemplation on if this project was worth the time and effort

Looking back at this project, it was the most consuming yet somewhat rewarding project we have done. I learned way more than I thought I would along with I have some pretty crazy ideas I want to implement using the plasma cutter (Christmas is coming up…).

Metal: $23 x 1 = $23

Spray Paint: $6.50 x 1 = $6.50

Filler Primer: $8.50×1 = $8.50

Plasma Cutter Rental: $15×2.5 = $37.50

Hourly Wage for Plasma Cutting: $17×6 = $102

Overall Cost: $177.50

I would do it again if I have plenty of time, haha. Also, I would love to do a project like this again and see what would have happened if I got to use the sand blaster:)