Black is the New Green

I used a plasma cutter to cut out steel into the shape of leaves and then used four post-processing techniques to improve its aesthetic. The process can be documented through the following steps:

  1. The diamond shape was downloaded and imported onto Adobe Illustrator (AI). A leaf icon was then downloaded as an SVG and scaled onto the diamond. This AI file was then sent to the plasma cutter computer and converted to Gcode using Torchmate. A sheet of metal was placed onto the plasma cutter and after grounding it and setting the origin, the leaf icon was male-cut three times. The following images show both sides of the plasma cut icon with slag clearly visible on one side.
  2. The first post-processing step focused on removing the slag from the product. This was accomplished by angle grinding the edges. 
  3. The next post-processing step was sanding the faces of the product to make the surface smooth to the touch and shiny. This was accomplished using an orbital sander with 200-grit sandpaper.
  4. The third post-processing step was to file the edges to make them smoother and remove most sharp edges.
  5. The final post-processing step was to spray-paint the product. This was accomplished in two coats of matte black spray paint while allowing 6 hours for the paint to dry each coat.
  6. The final product copies are shown below.

 

Cost Estimates

  1. Steel ($17.36/ft^2) = $0.72
  2. Plasma Cutter Time ($15/hr) = $1.25
  3. Angle Grinder ($0.0989/kWh)(0.33 h)(660W) = $0.022
  4. Metal Sheet Labor ($20/hr)(2) = $40
  5. Spray Paint ($0.017/mL)(20 mL) = $0.34

Total Cost = $42.33

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