Office Plasma Cutter

thingiverse

This is a CNC plasma cutter in an aluminium box for safely cutting metal next to your 3D printer. I use it for cutting metal parts in my office. It is vented and has an enclosure so sparks and fumes will be kept inside. - Build volume ca 750x350x10 - Ventilated housing to keep the cutting sparks inside and direct the fumes outside - Powered by RAMPS 1.4 with Marlin Firmware - 24V - All parts from Amazon, Ebay and local Hardware Store BOM: Frame: - 4x 1200mm 3030 aluminium profile - 8x 540mm 3030 aluminium profile - 16x 3030 corner brackets - 3030 x M5 T-nuts - M3x20mm screws - M5x20mm countersunk screws - M5x10mm screws - M5x12mm screws - M3 nuts - M5 nuts - washer 5,3x20x1,5 mm - 1x aluminium sheet metal 1200x600x5 - 3x aluminium sheet metal 1200x600x2 - 2x aluminium sheet metal 600x600x2 - 1x polycarbonate sheet 1100x400x3 - 2x hinge - 4x flap closure - 1x spigot Ø100 for exhaust air hose - 1x aluminum exhaust hose 6m - 4x ventilation grilles 70x70 - .>18,42m chimney sealing cord flat 30mm - 1,5mm² yellow/green grounding cable to connect all aluminium surfaces to each other and to the ground - cable lugs - 1x rubber mat 500x400 - 1x fitting 1 1/2" 90° - 1x fitting 1 1/2" double brass - 3030 x M5 sliding blocks - 1x 120mm plastic handle Y Axis: - 4x 590mm Ø12mm linear rod - 8x SK12 linear rod holder - 8x LM12UU - 2x 180mm 3030 aluminium profile - 2x 1190mm 3030 aluminium profile - 6x 3030 corner brackets - 3030 x M5 T-nuts - M5x10mm screws - M5x20mm screws - M4x20mm screws - M4 nuts - M5 nuts - 2x Nema 23 stepper motor - 2x GT2 10mm belt - 2x pulley 20T 6.35mm bore GT2 - cable drag chain 15x30mm - M8x30mm screws - M8 nuts - washer 8,4x16mm - washer 8,4x30mm - 8x Bearing 608 ZZ 8x22x7 mm X Axis: - 2x SBR12 rail 1000mm - 4x SBR12UU - M4x10 screws - 4x 130mm 2020 aluminium profile - 2x 400mm 2020 aluminium profile - 1x 90mm 2020 aluminium profile - 10x 2020 corner brackets - 2020 x M5 T-nuts - 3030 x M5 T-nuts - M5x8mm screws - M5x10mm screws - M5x20mm screws - M4x20mm screws - M4 nuts - M5 nuts - 1x Nema 23 stepper motor - 1x GT2 10mm belt - 1x pulley 20T 6.35mm bore GT2 - cable drag chain 10x20mm - M8x30mm screws - M8 nuts - washer 8,4x16mm - washer 8,4x30mm - 8x Bearing 608 ZZ 8x22x7 mm Z Axis: - 4x SK10 linear rod holder - 2x Ø10mm linear rod - 1x T8 leadscrew - 1x T8 nut - 1x 5mm to 8mm motor jaw shaft coupler - 2x LMH10UU - M5x10mm screws - 2020 x M5 T-nuts - Nema 17 stepper motor - M3x10mm screws - M3x20mm screws - M4x20mm screws - M3 nuts - M4 nuts Water Table: - 1x stainless steel tub 1100x450x70mm - 19x galvanized sheet metal 400x50x2mm - 2x galvanized U-profile 1,5x35,5x1000mm Electronics: - Display Case: https://www.thingiverse.com/thing:87250 - Fan Grill: https://www.thingiverse.com/thing:2802474 - case 500x400x175mm - IEC socket with fuse and switch - LED lamp 12-80V - ReprapDiscount Full Graphic Smart Controller - RAMPS 1.4 - 12V 6A Ø100 fan for exhaust air hose - 3x 12V 120mm fan - switch (enable/disable plasma trigger) - 2x WAGO 221-413 (for connecting the 12V 6A fan) - 4x WAGO 222-415 - 3x stepper driver Nema 23 - 1x stepper driver Nema 17 (for optional THC) - relais module - motor speed controller DC 9-50V 40A 2000W PWM - power supply 24V 20A - 2x DC DC converter 4,5-30V 12A (one for 12V 6A fan and one for RAMPS 1.4) - wiring channel - (optional) thermristor to show room temperature on display - labeling zip ties - normal zip ties - labeling machine (optional) - wire ferrules - cable lugs - cables 4x0,75mm² for stepper motors - cables 2x0,75mm² for plasma trigger - cables 1,5mm² brown, blue, yellow/green for AC wiring - cables 1,5mm² yellow/green for connecting the frame to ground - cables 1,5mm² red, black for DC wiring - standard stepper motor cable for connecting GND, EN, STEP, DIR to stepper motor driver - jumper wires to connect GND to EN-, DIR-, STEP- on stepper drivers - jumper wires to connect the relais module to RAMPS 1.4 - USB cable for programming RAMPS 1.4 You also need: - air compressor - plasma cutter (it´s important to use one with pilot arc because HF - Start can disturb the electronics) - window or good ventilation - fire extinguisher for safety if something goes wrong - towel if water leaks - safety glasses for welding/plasma cutting Setup: - I´ve uploaded my Marlin Setup. Upload it to your RAMPS 1.4 / Arduino Mega via the Arduino IDE and it should work. Operation: - For creating the drawings for cutting you can use Inkscape and Fusion 360 - For creating the cutting paths you can use Estlcam - In Estlcam you can save the paths as .gcode file on your pc or SD card - Then you can insert the SD card in the ReprapDiscount Full Graphic Smart Controller or control your RAMPS 1.4 board using your favorite slicer program - Move your plasma cutter to your desired start point and select on the ReprapDiscount Full Graphic Smart Controller prepare > set origin or send G92 X0 Y0 Z0 via your slicer software - Make sure the compressor and plasma cutter is running, the right amps setting is set, the ventilation is running and the plasma trigger switch is on - start your file - enjoy It is recommended to keep the door open when not in use to prevent the formation of moisture and possibly hydrogen when cutting aluminum https://youtu.be/VfcpGsx3_40