instructables

Home Built 4x8ft CNC Plasma Metal Cutting System

by Customfabricated

What is a CNC Plasma Cutting System? These are I designed and built this system in my personal shop
computer controlled machines that can cut through utilizing several o -the-shelf components along with
any electrically conductive material (steel / stainless / some custom fabricated assemblies.
aluminum / copper). The machine takes a 2D
computer generated sketch and translates it to a Check out the following steps for a detailed overview
computer numerical control (CNC) system that is of my custom CNC Plasma build!
coupled with a Plasma Cutter. The Plasma Cutter uses
an electrical arc and compressed air to cut through
the conductive material.

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Step 1: Planning and Components

Pla nning

Before beginning, I had to answer a couple key questions:

How large of a CNC table do I want to make?

What is the max thickness of material that I need to cut?

These two questions will drive the rest of your project. For me, I decided to build a table that can accommodate a
4x8ft sheet of material (4x8ft is one of the most common sizes for raw steel plate). Based on what I typically
fabricate, I wanted the ability to cut through 1/4in thick steel at a minimum.

I also included a few unique aspects into the design:

Drop down casters for easy mobility

Down draft system for drawing out dust and smoke
Nozzle point suction system and water trap for drawing out ne particles near the cutting tip
Removable cutting surface - allows me to lift o the cutting surface and insert a water pan for an
alternate method of smoke and dust control

Co m po ne nt s inv o lv e d

Below is a general list of the main components of a CNC plasma cutting system:

Pla s m a cut t e r - I elected to purchase a Hypertherm Powermax 65 plasma cutter for this build. This
machine is capable of cutting 1in thick steel.
Air co m pre s s o r - Plasma cutters require an air supply to operate and cut through materials. I
chose an Ingersoll 80 gallon air compressor which should have no issues keeping up with the air
supply demands from the system.

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CNC M o t o r Co nt ro l Pa cka g e - These are the drivers and motors that control the movement of
the Plasma Cutting torch. I purchased my system from a company called CandCNC. This system
included all 4 stepper motors and motor drivers in one complete package.
Ta ble B a s e - I custom fabricated my table base using raw materials. The main frame is built from
2in x 11ga square tubing.
G a nt ry As s e m bly - this includes all of the bearings, gears, gear tracks, and structural
components that make up the moving gantry on top of the table. You can source these parts
individually or purchase a full gantry kit. I elected to purchase my gantry from Precision Plasma.
S o f t w a re - a few di erent types of software are required:
CAD Design Software - Computer Aided Design software allows you to sketch and
design your parts before cutting them out. AutoCad or Fusion 360 are great options for
CAD design programs.
Plasma CAM Software - Computer Aided Manufacturing software will convert your CAD
sketch into a coding language (typically 'G-Code') that the CNC plasma system can read
and interpret. I run SheetCAM on my system.
CNC Control Software - this software reads G-Code and sends it to the motors on the
CNC table. My system uses Mach3 CNC control software

Co m put e r - a basic computer is required to run your CNC Control Software and hook up to your
motor control box

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Step 2: Fabricating the Table Base

I began by building the main frame using 2x2x11ga square tubing and 2x3x11ga rectangular tubing. I included
drop down casters that pin in place for easy mobility. I also extended my gantry rails such that the gantry will roll
completely o the 4x8ft area to allow for easy loading of steel sheets. The dimensions of the gantry drove the width
of the table base.

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Step 3: Fabricating the Cutting Surface

I designed the cutting surface as a removable assembly. This allows me to lift the surface up and insert a water pan
as an option for dust and smoke control. This cutting surface uses 2x1/8in sacri cial slats and was built using the
following materials:

2x3x11ga rect. tube

2x2x11ga square tube
1x1x14ga square tube
2x.25in at bar

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Step 4: Assembling the Table Base and Cutting Surface

The cutting surface drops into place on the table base. A set of 3in wide by 3/8in thick cold rolled at bars serve as
the rails for the gantry. Cold rolled materials maintain a higher dimensional tolerance than hot rolled. These rails

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bolt to the top of the main frame.

Step 5: Bench Testing the Motor Control System

Before attaching your motors and wiring, it is prudent
to bench test the system. This will ensure all your
motors and connections are fully operational and pre-
programmed to turn in the correct directions. The
instructions included with my CandCNC motor control
kit helped make this a straightforward process.
At this stage, I also wired up my Hypertherm Plasma
cutter so it will auto-start using a signal from the
CandCNC control box. The CancCNC instructions
walked me through this connection process.

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Step 6: Assembling the Gantry
After fabricating the table base and cutting surface,
the next step was to assemble and t check the
gantry. My gantry system from Precision Plasma was
built with extruded aluminum.
This gantry incorporates a Z-axis allowing for torch
height control (THC). Torch height control is a highly
desirable feature on CNC plasma tables. This allows
for active and automatic control of the distance
between the torch tip and the material being cut. A
voltage feedback system automatically maintains a
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speci ed distance even if the material being cut
begins to warp. Without THC, you run the risk of your
torch running into the work piece. A THC system also
prolongs the life of the plasma cutter consumables
(electrode / tip / nozzle).
I also opted to use belt reduction drive assemblies for
each motor. This helped to smooth out the operation
and movement of the gantry.
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Step 7: Building a Desk / Control Center

I fabricated a desk out of 1.5in square tube to house my computer and monitor. Some folks mount their computers
directly to the CNC base. I opted to keep this as a separate assembly. My computer is kept underneath the desk top.
I subsequently added some sheet metal around the desk to protect the computer from dust.

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Step 8: Adding a Downdraft System
An e cient means to draw out fumes and dust while
running a CNC plasma system is highly necessary.
There are two common methods for this: a water table
or a down draft. Each has its own set of advantages
and disadvantages
W a t e r Ta ble - this type involves a reservoir of water
(often times treated with a corrosion and bacteria
inhibitor) that sits just under the material being cut.
The water traps a large majority of the cutting dust
and helps to keep the material cool. However, water
often times splashes around while cutting and will
require constant maintenance to keep your gantry
system dry and clean
Do w ndra f t - this type uses mechanically driven air
ow to suck the dust and fumes down into the table
and out to a desired location. With the right fans and
enough air ow, this method works very well.
However, it does not provide the material cooling
capabilities that a water pan does. Keeping the
material cool is bene cial to reduce warping especially
when cutting thin materials.
I opted to incorporate a downdraft onto my table but
left the option open for a water table through the use
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of a removable cutting surface. I started by enclosing
the table base using aluminum sheet metal. I
plumbed in qty 4 suction points using 10in HVAC duct
work. Each suction point has a slider window that
allows me to direct maximum amounts of suction to
certain quadrants of the table. To power my
downdraft, I used two commercial grade kitchen
exhaust fans. These fans are typically mounted on a
roof or wall and expel air radially in all directions. I
modi ed the fans to expel air in a single direction
using some custom built duct work. My fans blow all
dust and fumes to the outside of my shop. Tip: nd
yourself a local HVAC wholesale company to purchase
your downdraft ductwork - this will be signi cantly
cheaper than the local big box home improvement
stores.
I subsequently also added a nozzle point suction
system. I used 1.5in sump pump drain hose and
routed it from the cutting tip, through my gantry
cable tracks, and down to a 5 gallon bucket which is
also connected to a shop vac. By partially lling the 5
gal bucket with water, I created a makeshift water
trap that helps to capture ne dust and particles.
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Step 9: Calibrating and Squaring the Gantry

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This is a critical step to ensure your system produces
accurate and true cuts. By physically measuring the
movements of the gantry and making slight
adjustments in the control system, you can dial in
your table ensuring a perfect 90 degrees between the
X-axis and Y-axis. I ran my gantry up and down the
table to ensure it remains even and true throughout
it's full range of motion. The 'limits' for the table are
controlled by microswitches. My CandCNC control
system user manual walked me through the
integration of the switches.

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Step 10: Test Cuts

After squaring up the system and completing all set-up steps from the CancCNC user manual, I was ready for some
test cuts. I followed the instructions from my control system manual and got to cutting. This system was ready to
work right from the get go. The rst cuts were crisp and clean.

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Step 11: Examples of CNC Plasma Projects

This table has changed the way I fabricate. Projects that would typically take days or weeks were cut down to a
matter of hours. Anytime I tackle something new, I rst consider how I can utilize the CNC table to build it quickly
and e ciently.

Here are a few projects I completed for myself and a few of my friends using this table.

See the next step for a video of the table in action.

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Step 12: Video of the Table in Action

Thanks for checking out my build and please feel free to ask questions in the comments section!

https://youtu.be/nrYRxeJ61gU

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If you are happy with Mach3 then fair enough, but I would like to point out that LinuxCNC now has
very good integration of Plasma, so that things like automatic torch-height correction (cut
corrugated iron...) and gantry squaring are fairly seamless.
Lots of info here: http://linuxcnc.org/docs/2.8/html/plasma/plasma-cn...
And here: http://linuxcnc.org/docs/2.8/html/plasma/plasmac-user-guide.html#cha:plasmac-user-
guide
I agree, linuxcnc is free (GNU) and it's realy good software.
For CAD I wood recomend FreeCad ( https://www.freecadweb.org/ ). It's good 3D software and
free (GNU) and it has it's own CAM module.
For orcanic moddeling (non-technical shapes) I would recomend Blender 3d
https://www.blender.org/ , also free (GNU).
Can we say that working on Linux is a better

Wicked! I build my own router CNC (as I mostly work with wood) but absolutely love what is done
with metal!
Thanks!

Good description. We built a 4x8 plasma table a couple of years ago. We only have a HyperTherm
45. If we need to cut thicker, we have an oxy/acetylene machine torch to put on it. We also
mounted a chuck that can turn up to 6" tubing/pipe so we can CNC cut it too. We enclosed the
electronics in a box about 20x20x20 and have two 150 cfm fans pulling air through a 1970s Ford
air cleaner for a 460 cid engine. We also used the CandCNC controls and stepper motors.
Could you give me an approximate cost of what it was to construct your plasma table?

I would say around $7000, which included $2000 HyperTherm 45, $2500 CandCNC controls and
motors, and a $700 machine torch. The rotary capability added about $600. We used (4) 24' pieces
of 2x3 rectangular tubing for the frame.
Love it. That's great stuff. Send some pics, would love to see it

Adding a CNC table to your shop is great, I have built a few tables from scratch and the cost is not
that bad, abut ($1500.) plus the Plasma unit. I have added optional attachments to mine to route
wood, drag knife sign vinyl and diamond etch metal. I have sold plans to over 14 countries.

//www.youtube.com/embed/fErYc7Wi1ps

Impressive work. Well done. Nice job. Look professional. I am surprised by how fast it is.

Thanks as you know you can have fun building one, and more fun with what you can do with it
after that. Adding a table is more possible than many think. The pink one was built for a lady doing
router work.

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This build is so helpful.
To paraphrase Robin Williams " God gave me a massive table and a box full of electronics, but not
enough Brains to get them to run at the same time". I think this instructable will get this project
back on the front burner for me.
Thanks! I had this on my to do list for years. I eventually decided one day that the only way to finish
it is to start it. I googled some info and starting buying parts. Before I knew it, I had a running
machine that completely changed my fabrication capabilities
This is a phenomenal piece of work, I must say. Not' like I don't have enough machines in the
garage, but but is brilliant, thanks for sharing it
thanks!

I used to work for a small company that built CNC cutting machines. I think the largest one we ever
built had a 20'+ gantry with a half dozen plasma torches. One of the smallest machines was for
cutting sheet metal and was about the size of yours. I did most of the design work and fabrication
(it was a very small company - about 4 of us plus the owner). I think your design is brilliant and
looks every bit as good as the ones we sold. There is one small difference that other builders might
consider. It won't improve functionality, but it might make it a bit easier to build. We used 80/20
aluminum extrusion for the side rails as well as the gantry which avoided the problem of cold rolled
steel often having warp and twist
You have built an incredibly versatile and useful machine. I hope you have fun using it.
thanks! I actually have a lot of scrap 80/20 that purchased from a friend and I am planning to use it
for a CNC router build
Could this be built to accommodate a wood cutting router?

Yes it can. The particular motor control system, gantry, and software I used is actually fully capable
of cnc router operations
Awesome! Have you tried putting plexiglass or lexan underneath a thin sheet of sacrificial metal for
spark? Then assemble in layers in bass relief for contouring? Always wanted to try it with led light
strips for accenting.
the sparks from the metal may get embedded in the plexyglass

Several advantages with building your own instead of buying one:

- Lower cost than retail purchase price.

- You can diagnose an issue without having to call in a service.
- Repair costs are lower.
Very good. In the 70's, I worked in a Colorado machine tool manufacturer (Heath Engineering) that
built oxy-fuel, optical tracing, shape cutters. In the 80's, the company started adding plasma
cutters, by the time ESAB bought us, we were working on a line of smaller "garage scale"
machines very similar to your idea. Having built quite a few of these, although many years ago and
quite different technology, I can say with some experience that this is a great tool, built right, and I
admire your work.
Really great project build & 'ible! Glad to see you've monetized it as well - paid for itself yet?

Ah, the beauty of instructables! :D

I enjoy seeing simple I-might-do-this-sometime projects, and in the next moment seeing insanely
complicated never-gonna-do-it projects, too!

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While I may never build anything like this, seeing your various techniques and final result are both
educational and inspirational. Well done all around, thank you for sharing this!
I feel the same way you do. From simple to complex, the creativity on display through Instructables
is amazing.
Thanks for the kind words! Glad to share! I too enjoy seeing the wide range of projects and
techniques posted here. Browsing through the projects always stirs up ideas for me!
I am a teacher at a Senior High School. We have a new Head of Department now, who is very
keen too 'drag our department into the 21st century.'
This idea of yours is awesome. I will let you know how I/we get on.
Thanks for this,
Domo Arigato,
Hitrd
(Heading in the right direction)

This would be an excellent project for a set of high school students to tackle. Let me know if you
have any questions along the way. Happy to help! Thanks
Nice. I bet it cost a small fortune though even with you doing the labour.

Thanks! In total (not including the plasma cutter and air compressor) I spent about 7k on
components and materials
Wow. Not bad. Cheaper than I thought. Out of curiosity how do you set z height on it? It must be a
certain distance for it to work, so is it set manually or? Just wondering.
This system has z-axis torch height control that automatically maintains a specified distance
between the tip and work piece. Prior to cutting, I set a THC voltage value in the control system
that is based on material type, thickness, and cutting amperage. This is a must have feature in my
opinion
Wow wow wow! Amazing work.

Thanks!

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