CNC Plasma Tube Cutter Light Weight Under 600$

This CNC-Plasma Cutter enables computer-controlled cutting of metal tubes. Designed for experienced makers and crafters, the plasma cutter can be easily replicated with personal tools or in local FabLabs thanks to its reduced complexity and detailed instructions. It promotes autonomy by enabling the creation of various frames and precise connections. I chose the size to be 800mm in length, so it can easily get carried to the outdoors and be portable. It's designed to run outdoors, since there are fumes forming while cutting. It fits ø35 - 200mm tubes.

1. Alu DIBOND (or similar) 4mm x 1m^2
2. End mill for plastic ø6mm
3. (r)PETG white 1000g
4. Ball bearings 8 x 22 x 7mm 16x
5. Threaded rod 8mm x 1000mm 3x
6. Plastic L-profile 1000mm
7. Cable chain 20 x 25mm x 1000mm
8. Track roller V-slot 5 x 24 x 10,23mm 3x
9. GT2 toothed belt 6 x 1000mm
10. Crate closure 13 x 49mm
11. GT2 Toothed loop belt 6 x 760mm
12. Alu profile 30 x 30 x 800mm 8mm groove B-Type 2x
13. Alu profile 30 x 60 x 800mm 8mm groove B-Type 1x
14. Slot nut M5 B-Type 9x
15. Alu angle profile 20 x 20 x 200mm 2x
16. Nema 17 stepper motor 1.7A 2x
17. GT2 pulley 16 - ø5 - 6mm 2x
18. Plasma cutter generator
19. Plasma cutting torch
20. GX16 connector 4pin 2x
21. CNC Electronic Board
22. DRV8825 2x
23. machine cable 20m
24. dupont connectors grid dimension 2,54mm
25. 12V 60W power supply
26. M8 screw nut 20x
27. 8.4 x 16 x 1.6mm washer 8x
28. M8x35 cylinder head screw 4x
29. M8x20 cylinder head screw 8x
30. M5x50 cylinder head screw 4x
31. M5x12 cylinder head screw 14x
32. M4x16 cylinder head screw 4x
33. M3x8 cylinder head screw 12x
34. M3 heat set inserts

Start by milling the DIBOND panels on a cnc-router. Leave some 3mm high bridges to secure the parts in the sheet while cutting. They can later be removed using a metal saw blade. Touch up the edges with a small file. Also deburr the holes using a deburring tool.

1. 0.6mm nozzle
2. 0.3mm resolution
3. 4 top + bottom layers
4. 4 perimeters
5. 25% gyroid infill
6. use support

Start by cutting 20 mm deep m8 threads in the faces of the alu b-type profiles using a tap wrench. Next cut the threaded rods to 830mm length each. Cut two alu angles, both 200mm long and drill a 5mm through hole, marking the center point at 15 x 15mm on both ends. Put the three threaded heat set inserts on the 3D-printed cutting torch mount, using a soldering iron. If needed redrill the holes in the cnc-machined and 3D-Printed parts. The screws should easily be pushed through them. Now all your parts are ready for the final assembly!

Extent the x-motor cable to 130mm and run it through the cable chain. Extent the y-motor cable to 50mm and connect each to a 4pin gx16 connector. Connect a 6meter cable to the other part of each connector. Unscrew the original plasma torch and transfer the hose package to the machine torch. Cut off the switch connector and connect the connector to a new 2 core 3meter cable. I build myself the Arduino-Nano-Estlcam-Board (which is a bit overkill for the machine) to connect to the motors, plasma and pc. I can't guaranty that the connection to the plasma generator will work with any other cnc board. It's best to have a board with a optocoupler that triggers the plasma.

Download Estlcam on a Windows pc and change the parameters according to the pictures. Upload the settings to your electronic board.

My tooling parameters for 2mm steel are ø1,5mm / Z+1mm / a(z+) 90° / F(xy) 1400mm/min / F(z) 1000mm/min / S 50000upm.

Always turn off the main switch of the plasma generator before placing and removing a metal tube in the machine

The tube will be extremely hot after cutting, use a pair of plumbing pliers

Wear UV eye protection