CNC Plasma using a ESP32 controller with fluidnc and fusion

[@tadwigdor8441]

Thanks for this. Lots of good info. Built a table for open builds and wanted to try fluidnc and this will help a ton.

[@acmcgow]

Great explanation. Thank you. Im almost done building my jd plasma table. I'm definitely going to buy your controller. Im looking forward to upgrading to your aluminum parts when they come available

[@juanandrescarri27]

Great explanation. Thank you.

[@JohanDegraeveAanscharius]

Oooooooo, was looking for this!!! Thanks a looooot!

[@dcmotive]

Glad it can help someone!

[@JonathanGOpara]

Awesome. Inspiring

[@markyu70]

Great! I used FluidNC for one CNC I made in 2021. Now I want to make plasma. Actually to add water pan and independent ESP32 THC controller to ATMega machine I have. Well I have one spare FluidNC control box (I made 6axes I2S PCB but only 4 x nema 34 stepper drivers for next CNC) but ATMega controller I use now (4axes) is packed with 4 nema 34 servo step drivers for 12.5Nm steppers and it would be big job to change it with ESP32 so I will leave controller I use now. I will make switch that THC ESP32 overtake control of Z axe when plasma is on and return it to ATMega when plasma is off just sending signals from ESP32 THC or from ATMega to servo stepper driver. Am I making mistake? Am I overlooked something? Thank you for advices. There are a few videos about toush screen THC I intend to use on my channel.

[@dcmotive]

When I have time I was going to do the same thing. A THC pretty much exactly how you described. Since I have the material touch off before each cut, it doesnt matter where the THC leaves the Z height at when done cutting. I havent decided yet if I will make the THC controlled from a simple manual potentiometer or tie the control into the settings in the fluidnc. It i can get standard cut voltage values, then it could be in the fluidnc, but if it often needs to be adjusted while in process then a local independent control would need to be used. But I think the less buttons and knobs to deal with the better.

[@thestickflicker]

I am doing something simular... any chance you would share you modifited Post Processor? thanks

[@dcmotive]

Sorry so late. Here is the one Im currently using. drive.google.com/file/d/1_6io300dWoSqXOyTO5LoXiIgQrvJibDv/view?usp=drive_link

[@ROBOROBOROBOROBO]

Is there a way to do probing the sheet metal, for uneven surfaces? I have seen some DIY setups which first creates a mesh and takes measurements with a probe then correcting the height as the plasma cutter moves

[@dcmotive]

With plasma cutting, thin metal will change shape during the entire cut process. So mapping doesnt work well, because it wont be the same in a few cuts. This program checks the height before each cut, but still thats not good enough for anything that has a continuous cut that is more than 6 inches or so in thin material. A THC would work best for plasma cutting thin metals. But I imagine water jet or laser cutting would work even better for thin metal as it doesnt heat the surrounding material as much. Even cutting 1/16" material is challenging to keep from warping. But what are you going to do with thin metal like that anyways, its too flimsy to be used in a fence or something structural, and even as a sign its a bit flimsy.

[@ROBOROBOROBOROBO]

@ ​​⁠thank you for your answer, and for thick plates don’t you need it for better cuts? Or is the difference so minimal that’s not needed

[@dcmotive]

@@ROBOROBOROBOROBO These setups wont really cut more than 1/2 plate. Besides it gets pretty heavy and hard to handle at that point. With the thicker metal you have to work with your amperage, air pressure and speed to get the cuts not too beveled. The Z axis isnt as critical.

[@ROBOROBOROBOROBO]

@ sounds great thank you, I also want to convert a manual machine to CNC with FluidNC and I want fusion 360 as CAM processor as it is my cad too. Nice to see this work setup works, i was worried if its possible as I lack experience, I guess post processor grbl works but i wanted to also use additional io of FluidNC controller for multiple things like coolant, air relay valve on off and so on I guess additional setup needs to be done for that

[@georgemuzek3862]

Thanks for taking the time to make this video it is very helpful would you be willing to share your fusion360 post processor?

[@dcmotive]

I think this is the current one I am using. I havent taken the time to really clean it up and make it plasma specific, but it works well for me for now. drive.google.com/file/d/1_6io300dWoSqXOyTO5LoXiIgQrvJibDv/view?usp=drive_link

[@Jorenclark]

Great video. Thank you! I'm converting a spindle CNC to plasma. The "RELAY" section of your .yaml.... Is that all you need to do? How do you assign that relay as the torch control? Is that what "tool_num: 100" is doing? Thanks again.

[@dcmotive]

The post processor in fusion is setup to use tool 100 for that operation, and that is what is tied to that relay in the yaml.

[@shanester2594]

What kind of jogging speeds are you able to get from fluidnc? Is the software limited as far as step generation? Thanks.

[@dcmotive]

I tried all kinds of settings and dont think the software limits you. My settings for my setup were 800 steps per mm for X and Y, and 200 for the Z. I limited my jogging speeds on the X to 1000 mm per min, because going faster would cause some chatter in the long lead screw setup. The Y was limited to 2000 and the Z 3000. Those speeds worked good for me.

[@shanester2594]

@dcmotive thanks for the reply. I want to build another plasmas. My old one ran linuxcnc. These little controllers seem pretty nice if the functionality is good enough. I will be on the lookout more videos.

[@TheLoup117]

What is the post processor that ou hare using in fusion360 ?

[@dcmotive]

Sorry so late. Here is the one Im using currently. drive.google.com/file/d/1_6io300dWoSqXOyTO5LoXiIgQrvJibDv/view?usp=drive_link