Plasma Table Build

[f150skidoo]

I was planning on updating my current plasma table with all new electronics, motors, and Z axis. But I changed my mind after ordering all the components and went with building a new table and selling my old one instead. Once changing directions I spent many hours designing the new table in CAD, I designed all the tubing to be laser cut so it would be all tab and slotted together to be as square and accurate as I could get it. I ordered all the electronics from Spark Robotics and opted for 5:1 planetary gear reduction, proximity sensors for the travel limits, and their Z axis with collision detection mount. Last week I picked up the pallet of parts from the laser cutter so I was able to start building the table over this past weekend.

 

[jack stand]

Looking forward to watching your table come to life!

 

[f150skidoo]

First thing to build was the top of the frame that supports the water pan. After squaring it up I put a few small welds to keep distortion to a minimum but not fall apart when I flipped it over to work on the bottom. Once flipped upside down I assembled the legs, cross members and fork pockets. I'm using 10 gauge end plates to add rigidity and to also serve as mounting service for the control box and plasma cutter shelf. Since my shop is tight on space I designed the table to have built in material storage with multiple shelf's to organize material by thickness.

 

[LXCam]

Count me in too.

 

[Bodj Built]

I'm totally stealing that material storage setup for my Plasmacam table!

 

[MadeByMiller]

Looking awesome!

 

[tarbellb]

Here comes a sweet build

Skidoo always finishes what he starts!

 

[mike93lx]

Looking forward to the build!

 

[f150skidoo]

On this project there will be roughly 250 holes that needed to be threaded, luckily I found a used tapping head off of FB Marketplace to make quick work of the threading. Next parts to fabricate is the X axis carriage with motor dust cover, along with the shelf that will hold my Hypertherm 45XP. The gantry riser side plates were next to build which consist of a 3/16" main plate, 1/4" bottom motor mount, and 2" tall 14 gauge stiffiners welded to the main riser plate and a bolt on cover plate so I can access the wiring that will run inside the riser.

 

[The Cobbler]

in for the journey. always enjoy f150skidoo's builds.

 

[fordkid88]

On this project there will be roughly 250 holes that needed to be threaded, luckily I found a used tapping head off of FB Marketplace to make quick work of the threading. Next parts to fabricate is the X axis carriage with motor dust cover, along with the shelf that will hold my Hypertherm 45XP. The gantry riser side plates were next to build which consist of a 3/16" main plate, 1/4" bottom motor mount, and 2" tall 14 gauge stiffiners welded to the main riser plate and a bolt on cover plate so I can access the wiring that will run inside the riser.

We'll get to tapping because I cant wait for the next progress update. Seriously great work, I'm going to borrow some design elements from you, especially the laser tab idea, wish I would have thought about that.

Which software route are you going?

 

[f150skidoo]

We'll get to tapping because I cant wait for the next progress update. Seriously great work, I'm going to borrow some design elements from you, especially the laser tab idea, wish I would have thought about that.

Which software route are you going?

Assuming your talking about control software? which is myplasma.

 

[f150skidoo]

With the welding of the motor mounts on the gantry risers I had some warping and wasn't happy with how the motor wouldn't sit flat. So I ordered a extra long 1" roughing end mill to square up the motor mount. Next component to work on was the water pan, I welded up the corners, added 1/2" NPT bungs for the drain, and welded in the slat holders. The water pan had to be made in two pieces due to the size of the unfolded flat pattern. I was originally going to splurge and have the water pan made from 304 SS but would've been significantly more expensive than the mild steel that I went with. But I'm planning on sending the pans out for zinc electroplating. The following step was to thread all the holes in the side rails and weld the gear rack on.

 

[f150skidoo]

The next step was to bolt the side rails on to the frame and mount the 15MM HIWIN linear rails. I then attached the risers to the linear rail bearing blocks and test fit the motor. After threading all the holes on the gantry tube I was first able to do a test fit then once happy tack the gantry tube to the risers along with the drag chain carrier.

 

[fordkid88]

Just out of curiosity how much did it cost to have your box tubing laser cut? I'm planning a build really similar to yours and just trying get a rough idea for pricing

 

[f150skidoo]

Just out of curiosity how much did it cost to have your box tubing laser cut? I'm planning a build really similar to yours and just trying get a rough idea for pricing

It was $1295 with them supplying the tube, I figured having the tube laser cut it was roughly double the cost of me buying the raw material myself.

 

[fordkid88]

It was $1295 with them supplying the tube, I figured having the tube laser cut it was roughly double the cost of me buying the raw material myself.

I was afraid you were gonna say something north of a $1000. I'm torn between doing it with a laser or slipping one of the machinist at work 100 bucks and having them drill and tap everything on one of the haas.

 

[f150skidoo]

Last thing to fabricate was the gantry motor covers. Next step was to paint everything, I ended up just painting the water pans instead of sending it out for plating. Hopefully I'll have the table assembled and operating in a weeks time.

 

[Monza Harry]

@f150skidoo really nice approach and execution with the integrated sheet storage solution! Convenience and excellent use of space all in one footprint! The added ballast doesn't hurt either. Harry

 

[f150skidoo]

One of the first jobs of assembly was to seal and bolt the two piece water table together, Once the sealant was dried I filled the table full and left it for a night for a leak test. After passing the test I proceeded to attach the control box and side rails with bearings. Next was to attach the gantry with the X axis to the lower frame and also place the slats in the water table. After completing assembling the main components I then started attaching the motors.

 

[f150skidoo]

After mounting the motors and Z axis I then began wiring up the proximity sensors and routing the wires and plasma torch through the gantry and cable drag chains. All the cables that were provided with the control package had 10 feet extra wire so I cut them all down to be routed as cleanly as possible to the control box. Tomorrow I plan on putting the table in its home and do some test cuts.

 

[MadeByMiller]

Bravo! That has to be the finest looking DIY plasma table I've ever seen! No surprise coming from you though, quality work as always.

 

[f150skidoo]

Bravo! That has to be the finest looking DIY plasma table I've ever seen! No surprise coming from you though, quality work as always.

Thanks, I always strive to make anything I build look factory made.

 

[fordkid88]

Thanks, I always strive to make anything I build look factory made.

This table is absolutely inspiring. I'm blaming you for the hundreds of dollars that have left my wallet recently as I've decided to do a similar build.

If you don't mind sharing, what do you have into this build. Ive been bouncing ideas off of our resident mechanical super genius at work and he asked why go through all of this, couldn't I buy one? I'm estimating $3,000, 4,300 with a different plasma cutter.

 

[mike93lx]

After mounting the motors and Z axis I then began wiring up the proximity sensors and routing the wires and plasma torch through the gantry and cable drag chains. All the cables that were provided with the control package had 10 feet extra wire so I cut them all down to be routed as cleanly as possible to the control box. Tomorrow I plan on putting the table in its home and do some test cuts.

Wow

 

[f150skidoo]

This table is absolutely inspiring. I'm blaming you for the hundreds of dollars that have left my wallet recently as I've decided to do a similar build.

If you don't mind sharing, what do you have into this build. Ive been bouncing ideas off of our resident mechanical super genius at work and he asked why go through all of this, couldn't I buy one? I'm estimating $3,000, 4,300 with a different plasma cutter.

I haven't actually added everything up but I would guess I'm in the range of $10-11K Canadian. I'm also using my Hypertherm 45XP and machine torch that was on my old table. The turnkey tables that I was looking at would've been close to $18k+ by the time I shipped them over the border.

 

[fordkid88]

I'm budget building mine, so import linear rails, avid cnc gear racks and drives. I'm going to do some machining to make my import steppers work. I get a discount on waterjet time and material from the shop I work at. I'm also going to rob all of my electronics from my little table. Otherwise I'd imagine I'm closer to 6-7000.

 

[Monza Harry]

I will jump on the wow band wagon! That is a truly impressive level of finish there. I'm capable of that but it seems that only happens at work where it has to. My own projects seem to stop at it works, well mostly, now I'm done. So that is a monumental level of persistence with the skill to back it up. Harry

 

[f150skidoo]

Got the table in its home, leveled, the plasma cutter hooked up, and the table grounded. I used some scrap to make some test cuts to get the machines parameters all set. Once I was happy with settings and I somewhat figured out the new control software it was time to cut some real parts in 1/4" plate. I was extremely impressed with the edge quality, the part in the picture was straight off the table with almost no dross on the back

 

[MadeByMiller]

Congratulations! The test cuts speak for themselves.

 

[fordkid88]

Those cuts turned out awesome. I don't know how I missed it but I love how you did your Y axis rails as slotted bolt ons. I take you did that to eliminate any twist and warping from welding

 

[f150skidoo]

Those cuts turned out awesome. I don't know how I missed it but I love how you did your Y axis rails as slotted bolt ons. I take you did that to eliminate any twist and warping from welding

Thanks, If you cant make something perfect it better be adjustable. I was toying with the idea of a fully welded Y axis rails and sending the entire table out and have the rails machined parallel but decided it wasn't worth the added time and expense. I figured the adjustable laser cut rails was my best option.

 

[tarbellb]

Thanks, If you cant make something perfect it better be adjustable. I was toying with the idea of a fully welded Y axis rails and sending the entire table out and have the rails machined parallel but decided it wasn't worth the added time and expense. I figured the adjustable laser cut rails was my best option.

This is so true, I implement this into many of my projects and try to extend this knowledge to others.

Table turned out badass, congrats.

And the best part.... just means we get to see even more projects coming out of your shop.