Mastering CNC Plasma Cutting: Technology, Operation, and CAM

How to setup, program, and operate a CNC plasma table 🔥
More Plasma Info: www.drdflo.com/Plasma.html
DIY Vacuum Lifter Plans: drdflo.com/Vacuum-Lifter.html
D-Flo's Amazon Store: www.amazon.com/shop/dr.d-flo
📷 Follow Dr. D-Flo on the Gram: / dr.dflo
Video Description:
Welcome to Dr. D-Flo’s mega guide on how to setup, operate, and perfect cuts on a CNC plasma cutter. This video covers everything from the basic principles of plasma generation all the way to programming the toolpaths that control the position and speed of the torch. Perhaps, the most important topic is optimizing both cut speed and quality to produce parts quickly without having to spend time on the backend grinding off excess dross. Unfortunately, there is not a universal setting as the performance of the plasma cutter changes as the consumables (electrode and nozzle) wear. This video will show you have to read the clues (i.e., lag lines) hidden in the edge to tune the speed, height, and amperage of the cut.
If you are new to plasma cutting, then you might not be aware of some of the challenges associated with fabricating parts from large sheets of metal, namely the material handling aspect. In this guide within a guide, learn why a vacuum lifter is the best method for handling thin and thick sheet metal and how to build one. This is just one of several projects featured at the end of the video.
#PlasmaCutting #MasterClass #Fabrication
Table of Contents:
00:00:00 - Introduction
00:01:02 - Workflow
00:06:07 - What is Plasma?
00:11:00 - Power Supply
00:17:51 - Torch Design
00:18:33 - Arc Ignition
00:20:22 - Pilot Arc
00:24:05 - Consumables
00:24:13 - Shield
00:24:53 - Nozzle
00:29:17 - Electrode
00:31:38 - Swirl Ring
00:34:32 - Retaining Cap
00:35:20 - SmartSYNC Cartridge
00:37:09 - FineCut Consumables
00:38:00 - Plasma Gas
00:47:42 - Plasma Shape
00:49:00 - Initial Height Sensing (IHC)
00:52:50 - Torch Height Control (THC)
00:55:17 - Plasma Cutting Sequence
00:57:28 - Minimizing Dross (Speed)
01:01:56 - CNC Table Design
01:07:57 - Material Handling
01:11:28 - Cutting Aluminum
01:14:06 - CAM/Toolpaths
01:26:12 - Nesting
01:31:32 - Vacuum Lifter
01:36:55 - Signage
01:37:38 - Fire Pit

[@DrDFlo]

As always, I am sorry for the long delay between videos. This content just take a tremendous amount of time to write, film, and edit. I wrote a blog post about why I make super long videos and the process if you are interested: www.drdflo.com/pages/Blog/Blog-post-23-10.html Let me know which section you found most useful and hit that like button to provide much needed motivation for my next mega guide!

[@dionisienatea3137]

Just a thought- an ultrasonic transducer may help removing the hydrogen bubbles

[@GroundedConceptsLLC]

Totally understand. Cannot thank you enough for the generous amount of information you contribute to the community. Keep it up brother and look forward to the next one!

[@amessersmith]

This is an absurdly well produced and researched video. I feel like you just crammed an entire plasma cnc course into this thing. Well done.

[@DrDFlo]

Appreciate it! I hope that plasma cutting technology doesn't advance too rapidly, so my video can remain relevant for a while lol

[@landongreer]

Hands down, one of the most concise yet deep videos on CNC plasma that I've seen. Nice work and thank you for creating such a great resource!

[@RokasSondaras]

Yup. Watching it for a second time.🎉

[@smellslikeupdog80]

Of course I wanted to start off my monday morning watching a deepdive on CNC torches. I just didn't know it until I started to watch this, and I've now been sucked down a rabbit hole of the CNC I always wanted. Like other videos, big thumbs up Dr. D; super high quality, super in depth. This is exactly what I come here for.

[@yoti-fab]

This is by far the most in depth plasmas cnc beginner guide I have seen. You did a great job breaking down all the different terminology and systems. 👍

[@wright.boy_]

Cannot believe this quality of content is available for free. Well done.

[@NoktiousGames]

Im only 40 minutes in but damn, this is well done. Its understood why your videos take so long to make, this is like taking a trade school program in a couple hours. Bravo.

[@Mrcensored1]

This is BY FAR the best video that you have made ! Thank you for this amazing content and helping this world learn and progress. God bless you !

[@robinstefanov5152]

Great video! Awesome structured, cover any aspect from plasma cutting from program side to the process itself . Thank you for making educational videos like this one !❤

[@abdolrahimziba3840]

It is really worth thanking for all the sacrifices you spent in the time and resources to teach this process. I would definitely like to follow your videos. Thank you.

[@7null]

Thanks for all the effort and LoD. Making this quality of videos is a ton of work.

[@srenfreiesleben1028]

Really what I needed :) I have made a DIY table and it is really good to have an in depth description and with a lot of theory :) Much appreciated Dr. D-Flo

[@DrDFlo]

You are exactly who I made this video for! When I was building my first table, I was having issues with cut angularity and short consumable life. Selfishly, this video would have saved me a lot of time and money. Best of luck cutting!

[@joshpit2003]

I think this is the best plasma cutting overview video ever created. Nicely done!

[@amazac9869]

very informative and comprehensive i can imagine the time and efforts you spent to prepare such an outstanding educational video thank you so much Dr.D-flo, cheers mate.

[@johnnytiepelman8880]

Clear, precise ,well filmed and edited. Covers the entire subject in depth . Actually a great example of how to do an informational video also

[@oswelds]

Well this is, hands down, the best guide of any genre on youtube. SUPERB!

[@sophtayl]

Brilliant tutorial video. So much to take away as I explore a cnc plasma bed. Thanks very much

[@johnbichell8023]

What an outstanding presentation. Information was detailed and your delivery is of a seasoned public speaker. Your graphics and pictures were excellent and delivered in a logical fashion. Super impressed!

[@plumber919]

Thank you for your time and effort! This is exactly the video I needed to see right now. We are retrofitting new hardware onto a commercial grade plasma cnc where I work and we are working with a Hypertherm 135. You have given a ton of useful information to help with the details. Thanks again!

[@ozzyoz6824]

man, you are REAL ENGINEER - respect!

[@lap87]

I did not even consider buying a cnc cutting machine until i had finished watching this, i followed for your top-notch printer videos xD Great video, great stuff, great guy

[@akrostonable]

Your videos are really informative, thanks for making them! This one is basically a reference video it's so thorough.

[@BecomingOffgrid]

I usually just watch your videos because you are entertaining. This video however was super useful to me because I have a sidekick 10 and hypertherm 85. Great content!!!

[@vincentpernicano3277]

Thanks Dr. Flo! Excellent presentation, education, and overall execution as always. The time between videos is well worth the wait! Cant believe you do not have 10x the subscribers!

[@Deeekf]

Thank you so much i recently bought plasma cutting table for myself and some of your tips would help defiently

[@stevesloan6775]

You are an amazing teacher. It’s so easy to follow everything you’re describing beautifully. 🇦🇺🤜🏼🤛🏼😎🍀

[@abdoukayan5377]

Love the amount of informations and the effort in this video

[@jesse2591]

This is absolutely amazing! Thank you for such a well put together and educational video!

[@thegremlin5886]

A fantastic and highly detailed explanation. Great job and thank you.

[@larspetersen2688]

Very impressive review of plasma cutting, I'm sure it took a lot of research to be able to do a review at that level.

[@RiteToRepair]

Excellent content! I have now learned my something new for the day, so thank you for that Dr.

[@m3chanist]

An absolute masterclass Dr, brilliant.

[@jamone50000]

Thank you for such great information

[@jamesfrancom8100]

very well done and super informative. thanx!

[@orhelyemreallok1811]

Köszönöm szépen! Nagyon sok mindenre kaptam

[@sergeyrodnov7566]

Very cool and interesting! Thanks.

[@SuperHaptics]

Awesome content Florian!

[@DudleyToolwright]

Very thorough and well done.

[@DrDFlo]

Thanks Dudley! Did you manage to through the whole thing?

[@JerodMatlock]

That was an awesome video👍

[@germantorres5907]

This is great content. Thanks

[@SirKuhnhero]

Great video. Now I only need a plasma cutter :)

[@sciencewins251]

what a video. Thank you!

[@mattsheehy1854]

Fantastic video! I learned so much!!

[@johnpekkala6941]

One important thing when working with plasma cutters is make sure in addition to safety glasses against the arc light to also always use proper hearing protection. In general from my own experience plasma cutters when operating are quite a bit louder then a compressed air gun at full blast and the noise is also even sharper and can quicly damage/destroy especially your high frequency hearing as well as give you tinnitus. Also air compressors are extremley loud (unless its a screw compressor but those are quite expensive). Plasma cutters are generally very noisy machines not just electrically but also soundwise.

[@fouzaialaa7962]

insanely educational , now i can claim to be an expert on cnc plasma cutting to my friends, i've given them the link too thx

[@DrDFlo]

Cheers, thanks man!

[@qpn6ph9q]

Thanks!

[@DrDFlo]

Appreciate it! Getting closer to that forklift 😜

[@redwhiteandbluebonnets8180]

When I saw this video was 1:39 I almost said nevermind, but I'm glad I didn't, this is a masterclass on plasma in the shop.

[@Poksutin]

this video is byfar the best on the internet.. even an idiot like me can understand plasmacutting now :) thank you for producing such an educating video :) cheers from finland!

[@ibrahimkasar9981]

Your are wonderful ! Thank you

[@randyjackson4282]

Very ! Very ! Well done.

[@user-ls9bd1xw4e]

I LOVE UR LECTURE

[@gudepurevanth3744]

Thanks a lot sir

[@marcus_w0]

View # 319 - helping out on your way to a couple of million views, to give you a forklift.

[@jackfranks7160]

For the Al G Rhythm!

[@DanielVierling]

Wow! Amazing video! Both informing and entertaining. You definitely deserve more Subs and Likes! How long did the editing on this video take anyway?

[@beachboardfan9544]

I dont think I've ever seen a shop run a plasma cutter on any setting other than the highest amperage and fastest IPM.

[@Fubuuuuu]

Good video

[@marcelloacker2693]

Awesome - very clear and nice video - everything in 1.5 hours that you must know abbout cnc plasm Where can i order the fluid for the watertable

[@Meusde]

ty

[@patelsteeltrading-steelrai6379]

Hi, fantastic job you did with lots of knowledge from different aspects. your efforts are more appreciable. I request to help me to know , whether the CNC plasma machine give me good cutting for Stainless steel 0.8 to 2mm thick alphabets cuttings, " Because I notice we are getting Burning marks on edges of LETTERS after cuttings, can we avoid of getting burning marks of stainless steel mirror polished surface? I am looking forward for your guidance, as i only found you as expert in this.

[@beachboardfan9544]

GOD D@MN this is a great video!! 👍

[@dionisienatea3137]

For all this pack of information, I cannot believe the number of comments and likes...

[@reinnwatson6765]

nice

[@kkofodh]

The reason Fusion changes direction with curf comp might be due to the fundamental code for CNC cutters with "Climb / Conventional" with mills. this is most likely a leftover since Fusion started as mill only, and its NOT based on the same kernel that most CAM software uses, but their own development (brought)

[@joeg9630]

What are your thoughts on the ArcDroid?

[@zip7806]

What is The Proper and Safe way to Drain Your Compressor tank? I just installed a Easy To reach Valve.

[@peterschuller2042]

Thank you for the great video and information! Do you have any specific information you can share on tolerances you are achieving on bolt holes? I know a lot of people make “center punch” type marks using pierce or even just pilot arc, then drill the holes. The suction cup rings you made in the video look like they have some pretty nice bolt holes, but I don’t know if you chased them with a drill, or used them as-is.. In your opinion, are bolt-ready holes 2X material thickness and larger (like 3/8 hole in 3/16 material, for example) possible? (Assuming proper tuning/setup)

[@DrDFlo]

When you cut small holes, you typically have lower travel speeds as the gantry is constantly changing direction. This gives the plasma the opportunity to search elsewhere for material to consume, resulting in low circularity. Yes, you can fire the torch briefly in a spot to create a pilot hole, but this hardens the material, so be prepared to go through quite a few drill bits. If you are interested in just making clearance holes, then the general rule is 2x material thickness as you mentioned, but no smaller than 2-3 mm (~0.1in). If you need to drill quite a few holes, then I highly recommend adding a spindle to your plasma table. And yes, the suction cup rings were plasma cut (not drilled), so if you are happy with that quality then go ahead and cut the holes out. Glad that you found the video useful!

[@peterschuller2042]

@@DrDFlo Thank you! All makes sense, much appreciated. great stuff here!!

[@frankljs]

What’s the brand of your fixture table? Thanks

[@jamesfrancom8100]

what about the oil in the air lines?

[@lucoot]

What prevents the table slats from accumulating damage so quickly that they no longer provide even support? I wonder the same for water jet.

[@DrDFlo]

Largely depends on the geometries that you are cutting. Zig-zags and other repetitive features near the same slats will damage them quickly. Fortunately, the plasma cutter can cut out its own slats from left over material.

[@stoffel89]

I have the opportunity to get my hands on a plasma table with a hypertherm 45 xp. one problem, there is no laptop. its missing. Im assuming I can replace the main bord with either a blackbox, or arduino and cnc shield operated with GRBL or lightburn. but how do i manually test the plasma cutter. the hand held torch is missing. only have the torch that fits the z axis

[@QuebecoisSti]

I am doing my own plasma cutting table right now using Centroid Acorn controller. Not done completely yet, still missing the water table but the rest is almost done. Centroid told me I could use SheetCAM software for sending G-Code but Fusion360 looks nice. Can we chance the lead-in and lead-out made in Fusion ? Is it possible to have radius and adjust them manually ? Can Fusion do smart nesting on whole plate automatically (just add files and make it fit the best and taking the less space for it) ? Furthermore, maybe there's a way to even try achieving True Hole technology by applying some concepts of the bigger HPR unit from Hypertherm (i am using a 45XP) I am wondering if it could worth it to go using Fusion360... since it needs a monthly paid service instead of one time cost

[@QuebecoisSti]

I just found on Centroid Forum that the post-processor exist for the Acorn Plasma in Fusion 360.

[@bikefarmtaiwan1800]

Look who's setting a new standard !! Well done to you - very well done on all levels .

[@Dev_Everything]

How is your machine so clean? Do you never use it?

[@DrDFlo]

I wiped down the table before filming 🤷‍♂️

[@Aj.Studio537]

Friend, what is the problem with our plasma cutter? Why is it not working

[@WoLpH]

This is a fantastic video and the quality is amazing and I loved watching it... but I would strongly recommend to go for a slightly different format instead. Releasing multiple videos and putting them all in a playlist so people can jump around like that. Generally I immediately click on your videos, but a video with this duration is hard to fit in my schedule and there's no good way to split up a youtube video in multiple watch sessions in my opinion.

[@DrDFlo]

Totally understand your point of view. But I didn't want to overload my channel with 25 plasma cutting videos. Also, I am targeting a specific person, someone like me who bought or built a plasma table and is having issues with the cut. When I was first getting started, I went through days of troubleshooting, and would have been more than willing to watch a video of this length. Narrow vision, yes, but this has been a common thread for my videos. But thanks for checking it out!

[@WoLpH]

​@@DrDFloI definitely see your point and I'm not sure how well a split video would work in this case. At least the timelapses and CAM parts could have been separate but that wouldn't help all that much. Thank you for the wealth of information in any case, I have no immediate plans to get a CNC plasma cutter but I have thoroughly enjoyed learning more about the process :)

[@bpdp379]

Just save the video to “Watch Later” playlist….return at your leisure.

[@Gjed16]

😊😊😊

[@Steelcrafted]

Man you should really look into sheetcam.....if i had to do cam in fusion 360 for plasma, I'd lose my mind.....sheetcam just takes a dxf, and in 1 click gives you your toolpath..... handles nesting, arranging, all that.....spits out g-code with another click...way better than fusion for cnc plasma

[@TheBoatman11]

👍👍👍👍👍👍👍

[@Aj.Studio537]

Friends we started plasma Cut after starting After starting, the cutting nozzle drains water After setting the program A plasma cutter does not cut Because the coolant flow on optional On the display of the plasma cutter plasma didn't start ARC was lost Friend is that we are the problem Will explain it

[@RockHoundsShow]

That gantry seems really overkill for plasma, wouldn't its weight reduce your performance especially cornering?.

[@DrDFlo]

Yes you are correct. The steel gantry is very heavy and it reduces accels, but it is also less likely to get bent if I bump a ~300 lb piece of 1/4" steel plate into it during loading.

[@rochamocha5705]

bro where's the benchy

[@remustrading]

Awsome video! Thanks!

[@cecilia_mackie]

Marvelous! Let’s be friends?

[@wspad2136]

Thanks!