This week, we were tasked to use the plasma cutter to cut out two metal pieces shaped like diamonds. This blog post documents my experience using the plasma cutter and employing various post-process techniques to provide a finished product with clear and prominent details.
First, I created my design to cut out the two metal diamonds. Using Adobe Illustrator, I generated a DXF file with the outline of New York State and proceeded to upload this file into the Torch Mate program in the plasma cutter during my TA session. At this time, I learned the proper etiquette and approach to use the plasma cutter, and the software used to upload and cut out my two pieces. Although the cutting process produced unwanted metal dross, I was very satisfied with the cut as it cut out a clear and defined outline of the design.
Following using the plasma cutter, I was finally able to commence post-processing, in which I underwent multiple processes, with a few hiccups. First, I wanted to address the unnecessary metal dross on the outline of the two diamonds. I found the best way to remove this dross was to use metal pliers, in contrast to the angle grinder. It provided substantially more control than the grinder while also proving a far more time-efficient process. Then I commenced to angle grind to remove the excess mill scale, rust, and other notable discrepancies to develop a smooth and polished surface. This is when I made my biggest mistake of the entire project; I did not angle grind enough on the diamonds, which later resulted in a patchy finish.
(Taken mid-way through angle grinding process)
But unknowingly, this, I continued onward to the next step of filling to smooth out rough edges. Then I started sandblasting to rid the surface of any other microscopic contaminants and provide a smooth finish before adding the powder coat. This process did take longer than expected, but that was partly due to the time I didn’t use with the angle grinder. But overall it provided a uniform surface.
Once all was said and done, I began to powder coat the surfaces of my diamonds with a purple coat, and after setting up the area and pre-heating the oven, I began to produce what I thought was a uniform coat. But after the recommended curing process of 20 minutes, I noticed that my coat had a nice pigment. However, some parts of the powder did not stick adequately to parts of the surface (of both diamonds), resulting in patchy, dark, and bright spots across the surface. But I also noticed a lip on one of the sides of the diamond, so I tried to combat that by sanding down the excess. That produced a metal piece that I was not satisfied with. Thus, I wanted to add a second layer of coat. Still, I ran into the issue of the coat not being uniformly distributed, so to solve the problem, I decided to sandblast the pieces again, providing a far more uniform and conducive surface for powder to stick to. So I went through the curing process again, and produced two diamonds that I view as more aesthetically pleasing, as they have
a darker pigment to them, although some issues still remain, they are present at a smaller scale.
Cost Analysis ~
Labor ~ $21.75
Hours : 3 (At Texas Minimum Wage) = $21.75
Materials ~ $5.58
Steel Sheet: 15 square inches (At $0.14 per square inch) = $2.07
Powder Coat: 1 ounce (At $3.51 per ounce) = $3.51
Equipment ~ $1.67
Maker Bar Space: 1 Day use for Monthly Membership at $50 a month = $1.67
Total = $29
I thoroughly enjoyed this project as it gave me another insight into metal cutting and post-processing. Although I did make mistakes along the way, I am satisfied with my two finished products, and now I have the knowledge and experience to apply these techniques to my future endeavors.
(P.S. I did not know someone else had also cut out the outline of New York City until I plasma cut the two diamond pieces.
