Making a Torch Splash Guard | Langmuir Crossfire Software Workflow | Fusion 360 Sheet Metal

Lots of people have been asking for a video on the software workflow for the Langmuir Systems Crossfire plasma table. Admittedly, the manufacturer's videos and documentation are lacking, so I'll take a run at it today. We'll design a splash guard for the torch handle out of aluminum sheet metal, cut it out, and bend it into shape.
Stuff used in this video:
*This site contains affiliate links for which I may be compensated
Hypertherm Powermax 30 XP Plasma Cutter (eBay*): ebay.to/2JgTrK6
Rhino Cart Welding Fixture Table (Amazon*): amzn.to/3za8aez
Milwaukee Brushless Right Angle Die Grinder (Amazon*): amzn.to/3j8pqeh
3M 2" Roloc Disc Adapter (Amazon*): amzn.to/3E39hyX
Scotch-Brite Surface Conditioning Disc (Amazon*): amzn.to/3p9zxDj
Noga Deburring Set (Amazon*): amzn.to/2xMfiPz
.050" 5052 Aluminum Sheet (eBay*): ebay.us/qoKZwr
Beelink T34 M Mini PC (Amazon*): amzn.to/3nwjy1m
ASUS 21.5" Touch Monitor (Amazon*): amzn.to/3B7MbW4
Yeti Rambler 14oz Mug (Amazon*): amzn.to/3nAC59q
Raw Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0 License
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[@Sbregher]

The best how-to video ever!!! Thanks a million for taking the time to create it!

[@made_by_chris]

I've been on fusion 360 for 3 weeks now. This video helped me more than most others that I've watched. And you put it out yesterday on my bday. Double treat! Thanks!!

[@danielminskey]

watch lars christansons fusion videos they are pretty good..

[@ab_customz_llc]

Thank you for taking the time to walk through the process step by step. I really salute you for breaking down the G-code portion. That is an area your average DIY guy doesn't quite understand. Much appreciated!!

[@David_Best]

Great video, as always James. I love the variety of your content. I look forward to your weekend videos as much as I did when I was 10 and looking forward to Mr. Wizard. I always learn something. Much appreciated.

[@chrisj4570g]

Thank you for waking through the G code. I’ve always wondered how the language was deciphered. 👊

[@mumblbeebee6546]

I have none of that equipment, nor do I know whether I ever will - but thank you just the same for making such great tutorial videos of the engineering that you do!

[@cwgreen1938]

Boy James, you have got the best play pretties that anyone could ask for. I enjoyed your video.

[@bigmc5706]

Dam you are such a cleaver puppy !!!. Your videos are so informative and well produced. I myself have learnt so much with what one needs to do in the design process so thank you for your video again. I'm sure others who needed some clarity with Fusion 360 like I did are now breathing a BIG sigh of relief after your video. GREAT JOB James

[@craigsuslosky3974]

Great job!! I like that you go through the F360 drawing of the part and explain why you do certain steps that you do. One day I will upgrade my computer and give F360 a try. I will never have any CNC equipment, but I love the drawings you produce. It is also nice to see it on the screen, and check out in 3D if there will be any issues. Thank you again for sharing your knowledge, and projects!!

[@milanteubel8389]

I love this channel. Please never stop showing us all your new toys and engineering endeavors.

[@BigNicky77]

Wow! What a fantastic video for a prospective buyer. Definitely takes some of the anxiety out of learning the design process. Thanks you!

[@sincityhvacr]

thank you very much man been looking everywhere to get better with fusion , thank you

[@bigrednick100]

Best video I’ve seen this far for designing in fusion from start to finish. Well done.

[@azenginerd9498]

To streamline our bending operations, I add small 1/8" x 1/8" tabs aligned with the bend lines on the edges of the flat pattern (predefined as a drag-n-drop library feature) . The bending tech just lines up the tabs with the edge of the break. Yes, the tabs need to be ground off after bending. But the need to transfer bend info from a drawing to the flat pattern blank (or many blanks) is eliminated. It provides a substantial net gain and reduced scrap.

[@Clough42]

That's a great idea. I know some people perforate the bends as well. I'm not familiar with library features. Maybe I need to do some research.

[@cooperised]

@@Clough42 Or you could go full Shane ("stuff made here") and add a retractable Sharpie as a second tool. He cuts the part and marks the bends all in one go.

[@4legdfishman]

Wow! Amazing! You covered pretty much everything I need to know in order to make my first cut on my Crossfire Pro! Thanks so much for taking the time to share your experience and knowledge.

[@PM.al.whatmough]

Excellent video. You did such a nice job explaining the end-end process

[@matthewsentman5016]

Thank you so much for your videos! Extremely helpful. Keep up the great work!!

[@notsonominal]

That clearly worked on the first cut:P Thanks for sharing, you're really getting the hang of this whole youtube thing lately!

[@stephenormsby3662]

Very informative. Thanks for posting.

[@JackInTheShop]

Great video. I have just bought a Cut60DN. I plan to add it to my 30X30 Longmill CNC router. I have a small shop. Don't have the room for another large machine with the Longmill on one wall and the 60Watt CO2 on the other wall. I have Vcarve. I all but forgot about Fusion CAM. Everyone talking about Sheetcam, I am not ready to make a software purchase right now. This video has helped tons. Thanks

[@samvoelkel2046]

I learned several things from this video. Thanks.

[@joell439]

thanks for the tutorial - I really appreciate all the detail.

[@DougsMessyGarage]

Great demonstration. I am seriously drooling over the Crossfire Pro, I expect there will be one in my shop sometime in 2022.

[@appalachianman824]

Awesome video

[@i_might_be_lying]

You might want to add Air Scriber to your setup to automatically mark the bend lines, like on more professional machines. Also, the wire brush cup is a great at cleaning dross from plasma cut parts (the braided wire cup for steel and stainless steel - don't know about aluminum).

[@rpavlik1]

"Stuff Made Here" has some videos on the sharpie he added to his plasma cutter.

[@deejayb71]

I appreciate your excellent video and presentation - subscribed.

[@alexchliwnyj5941]

Great tutorial, I just got a metal brake and this really helps.

[@ahbushnell1]

You did a great job.

[@mabmachine]

Great video. I really enjoyed you showing the G code breakdown. I have a Crossfire Pro with THC and a Hypertherm 65 with machine torch. If you haven't seen it yet Hypertherm's new Powermax Sync series (replaces the 65/85/105 cutters) is awesome. One piece consumable package that the machines recognizes when installed and adjusts settings accordingly. The machine also tracks the number of pierces, dry fires, and cut time for each consumable package.

[@k2line706]

I really appreciate you going through the GCode.

[@azenginerd9498]

I use SolidWorks but I suspect F360 has similar functionality - an option when creating the 55° flanges is to select both edges in the initial feature and eliminate the need for the mirror feature.

[@mattym8]

You are correct.

[@Clough42]

Oh, cool. I didn't think to try that.

[@kendesign3622]

I was going to say the same thing 👍

[@KristopherGrove]

Great stuff, James! Hoping the spot welder comment was foreshadowing.

[@stefanjetchick3853]

I was about to say, he sounds like he wants to imitate Dan Gelbart, i.e. "The Keystone Predator of the Maker Community" on KZbin. Dan Gelbart has the most impressive home shop of them all. And he loves his spot welder!

[@eberseth]

Great video! I can already see a future project...an angular DRO for your brake.

[@joeldriver381]

He is totally going to make a StuffMadeHere style Sharpie plotter for it.

[@Ale_Lab]

I thought the same thing. That upgrade is great but you need an open CNC controller for that. Not sure what is used on the Crossfire.

[@SaltCityFab]

I hope so!

[@Clough42]

Exactly. This is the downside of the closed system. The upside is that it just worked on the first try.

[@Ale_Lab]

@@Clough42 Yeh thought so, well Mach3 can also be used with Plasma. Of course is nice to have a plug and play product. I did not know the company before you posted. Looks really good for the price.

[@Clough42]

@@Ale_Lab I've never been super happy with Mach. I'm thinking about centroid acorn for my next machine.

[@wags9777]

Cutting edge engineering channel from Australia says inch measurements are in bananas. I literally laugh out loud every time.

[@Clough42]

Yeah, it's a great gag. Keeps it lighthearted. Some people get really worked up about it.

[@lwilton]

@@Clough42 I was just watching a new video from RotarySMP where he showed a quick picture of a green plastic banana ruler. Given that it was curved I had to wonder if it was made in France.

[@richardclark375]

I like inch too, but I’m a 60 year old manufacturing engr., so I have to use both!

[@Clough42]

Yup. I use both interchangeably, depending which is easier for a given situation.

[@9z4clb]

Great video as always James. Hope you have good ventilation in your shop (I've got an extractor fan setup). I use AutoCAD 2007 for my layout work (cause I'm fast with it) and SheetCam for my post processor. My Crossfire Pro uses Mach3 and I've built my own Z-axis and THC (the Langmuir forum has comprehensive details). I get minimal dross forming on my cuts (nicely tweaked post-process tools) and the best way I've found for dross removal is simply knocking it off with an ordinary steel paint-scraper. Touch-up on my wire wheel rarely needed.

[@LeeJones-mh5df]

Hey James aka clough 42, I've watched most of your videos, and learned alot. I've noticed you printed bends on paper and transfered to sheet metal. I'm sure u already thought of it, and I've just missed it. But if not. Why not put sheet metal on plasma table, and add a holder attachment to scratch your bends and cuts. Maybe even cut your cuts with torch. If not just to scratch bends from fusion. No paper needed. I'm sure for small stuff paper may be easier ect. just a thought. Keep learning and sharing. It's appreciated . Thanks

[@Clough42]

The Stuff Made Here style sharpie holder would be handy, but the Langmuir electronics are closed and not easily extensible to add that. It's technically possible to take out the torch and replace it with a scribe and run a separate GCODE program just for that, but it seems like a lot of work, with a lot of risk of the part moving, since it's just sitting on the slats of the table.

[@tadamb1]

Thanks!

[@danapatelzick594]

Pretty cool. F360 seems to have a capable sheet metal program. I am not sure about the brake but maybe it grows on you. The plasma cutter look very capable, there are a number of applications that would be interesting to try out.

[@Steve_R]

Nicely done James. I'm going to guess that you have a video in the works about a spot welder that you bought. 😀

[@MalcolmReynolds14]

Oh yeah, spot welder video please!

[@tadamb1]

Thanks James. This was all feeling pretty overwhelming. This video was a huge help. Still think you should have just used a crazy long extension cord in lieu of a transformer to reduce voltage on your brake though [laughy face picture thing].

[@AmateurRedneckWorkshop]

Nice project and nice outcome. You certainly have the best of tools. I was sort of surprised at the horizontal position of the torch.

[@Clough42]

Surprised at the horizontal position? Not sure I understand.

[@AmateurRedneckWorkshop]

@@Clough42 dedicated cnc plasma torches are available that are straight and stand vertical in the Z axis. I bought an Everlast plasma with the cnc torch but I had a vertical torch before it.

[@frankward709]

That is a very neat break for a small shop and I have a Hypertherm 85 I just need to get me a table or build one Like your video very well Thanks I'm Frank

[@donswords6671]

Great video!! After all design done and PP, I can’t get my torch to light or if it does, it goes out right away. I’ve changed the Pierce delay back and forth, the torch works fine with the test feature. ??? I’ll try on Langmuir forum. Thanks again this is a great video that allows me to get used to the many different functions of fusion 360 as practice for design.

[@osumailguy]

Gather around kids …another Clough42 video has dropped!

[@DimensionMachine]

Great vid showing the entire work flow. Am I the only one that noticed the mess that was made by one of the hole pierces landing right on a table slat....I hate it when that happens!

[@Clough42]

It happens. The die grinder makes short work of it

[@DEtchells]

Great vid, James! I’m planning on getting a Langmuir table just like yours (purchase is maybe a year away though), so this was *super* helpful! I love the touch-screen monitor for running the table from, what mfr and model is it? Easy to integrate the touch control with the computer?

[@danielminskey]

Planar makes a nice one..not to expensive either...amazon

[@mrechbreger]

Sience of Sheet Metal... looks so simple but can be so difficult. I had to deal with that myself just some time ago a small 8mm u-channel including micro-milling. The fiber laser cutting quotes are still not available unfortunately for my copper parts but even then the part I need is a multistage processing part.

[@theundergroundesd]

I have a old school finger break. I dont see the advantage of yours. I like the cutting table. Keep up the good work.

[@ericsandberg3167]

Man, you made short work out of that........I see lots of sheetmetal parts in your future....😎

[@danielrogers6090]

Good work James i really like you tool post grinder videos as well i need to build one that spins at around 40k though for grinding small boars in carbide. Anyway im a tool and die maker by trade and now am a full time tooling engineer and im proud of yor work buddy i just got a crossfire pro as well and can cut 3/16 all day with a + or - .005 all day its a great machine and keep up the great content

[@Clough42]

Which torch are you using? I think the 30XP I have would struggle with the duty cycle on that.

[@danielrogers6090]

Im running the prime weld cut 60 on a well grounded 50 amp breaker

[@danielrogers6090]

What type and how thick is the material you are cutting

[@MrSneakyGunz]

3:10 American units are the Bees Knees. 😁

[@sean7193]

when you originally purchased the crossfire 2x2 did you get it with the THC from the start? or did you add it later? do you find its a big necessity?

[@phil.tsao.]

I notice you have a 30XP like I do! Just wondering which consumable type you use (standard vs fine cut) and whether you're running off 120 or 240? Most of what I will cut is

[@bobweiram6321]

How about building a built-in digital angle gauge for the brake? The digital angle cubes probably work just as well. Having to guess the correct lifting angle by trial and error is not only cumbersome, but incongruous with the all bells and whistles of the brake.

[@rodentofanger1720]

Greetings James, thank you again for a great video. I do really like the Fusion 360 portions as I am learning (slowly) Fusion 360. I seemed to have downloaded Frustration 360 instead though. Going through the Gcode was great. Like you I want to understand all the parts of the process and not just believe it was magic pixies. With regard to bending the correct angle in the sheet metal brake, would you concider making a mechanical pantograph style angle display gauge? That might be a fun project. All it needs to do is indicate ( move a needle or linear bar ) the angle you pull up the front of the brake and let you know just how much your bend is. It would use all your fun toys. Cheers and stay well.

[@Clough42]

The bending arm has a sliding scale built in. To get a final bend of 50 degrees, I was planning to pull it to 55, but I was focused on filming, and when I looked down, I was at 70. Oops.

[@rodentofanger1720]

@@Clough42 Greetings James. Boy do I know that feeling. It would be cool to see the gauge at work sometime. I would love to have one of those Brakes. Also did you ever go over the electronics circuit to see if it really does draw 17A and Baliegh just got it wrong? "Curiouser and curiouser" said Alice...

[@Clough42]

@@rodentofanger1720 yes. Despite all the passionate comment threads, it really does draw that much. Hard to say whether they got it wrong from the beginning, or if components from their suppliers changed over time. The tech support people I spoke with at Baileigh were super helpful with parts and service, but didn't seem very knowledgeable about the electrical design, so I would just be guessing.

[@CatalinMinulescu]

Hi and thanks, I have just discovered your video. If you don't mind and you can tell me, I saw you are using a non genuine Langmuire plasma table. Could you tell me what electronics did you use in it ? I dont' mean the drivers, or motors, but what board. It's a GRBL DLC 32 ? Thank you in advance. All my best wishes from France !

[@jjbode1]

Which way will moisture weep from the torch side of these shields? I'm sure some will splash there regardless.

[@Clough42]

It would flow down and drain through the bend reliefs, but in practice, I haven't seen any moisture make it up there.

[@nathanrice7352]

Hi James, where do you source your raw materials from? Having a half a time finding a local supplier for the random odds and ends I need.

[@jhawker2895]

Wonderful presentation as always. Thanks for sharing. Is the cost of sheet metal going up like everything else?

[@Clough42]

I just started buying sheet metal, so I have no reference. So it doesn't make me unhappy. :)

[@andrewtreloar7389]

Hi James, great video mate!! Do you recommend the Langmuir Plasma table? I take it yours is the Crossfire?

[@Clough42]

Mine is the 25x33 crossfire. As an entry-level machine for hobby work, in happy with it. If I were doing production work in a large shop, I would want a deeper water table, but I really wouldn't want that in my garage, because then I couldn't move it around.

[@andrewtreloar7389]

@@Clough42 Thanks for the response James, appreciated.

[@drpipe]

Do you have to use a Gas mix to cut Ali ? I know you can use just air with Ferous metals

[@Clough42]

Nope. Just air.

[@drpipe]

@@Clough42 thank you 🙏 Definitely on my To buy list now. Big thank you for the work process.. I’m used to 3d printing so had an idea.. never used the sheet enviro in fusion but boy is that slick. 🙏🙏

[@crabmansteve6844]

Your movement in this software is excellent, did the space mouse make that much of a difference?

[@zwillx3953]

Oh wow yeah he does use that. Deleting my other question 😂 Just knew it looked different

[@Clough42]

Yes. Highly recommended. I did some modeling in a hotel room last weekend without it, and I immediately ordered a wireless one to take with me on the road.

[@lwilton]

@@Clough42 I was wondering how you were flipping the part around and resizing the image when it looked like the mouse cursor was off to the side and not on the part. A short tutorial on how to actually manhandle the drawing while working on it would be appreciated.

[@Clough42]

@@lwilton there isn't much to it. The SpaceMouse is just a knob that manipulates the part in 3D space, independent of everything else.

[@markpinkstaff2287]

Very good, all new to this and while your instru8ction is a bit fast for me at least I can go back and forth and catch it all......c

[@Sharedbook]

Great stuff!!! I was wondering why you didn’t go for Avid CNC plasma cutter system?

[@Clough42]

The Avid setup is significantly more expensive. I didn't really even consider it at the time.

[@Sharedbook]

@@Clough42 I was thinking the same. Thank you!

[@DavidtheSwarfer]

Plasma cutting is cool , envious….

[@Boogie3D]

Do you plan to add the marker like "Stuff made here" did?

[@Clough42]

The Langmuir FireControl electronics and software are a closed system, so adding something like that would probably require replacing them.

[@scrout]

Would love to see you mod your plasma with something like a Lightburn camera....

[@mrtnsnp]

Previewing on the table may be easier with a sharpie in a spring-loaded holder (same diameter as the torch).

[@Clough42]

Thought about it.

[@LabRatJason]

Came to the comments for the metric vs. imperial rage... was sorely disappointed. It's like the internet is getting more docile every day! Maybe it's James' calm demeanor?

[@Boogie3D]

There is just one, clear winner. No more fights are needed ;)

[@woodendog2888]

The way I look at the inches vs metric debate is if you can hit your dimensions then it doesn't matter what you use. My buddy uses inches on his late because its an imperial lathe but when he's doing anything else its metric. Whatever is easiest and quickest and once your finished then you can spend the rest of your time arguing over which is better.

[@RCDinsmore]

It looks like you might want to figure a way to keep the torch cable/hose from hitting the sharp/hot metal on the talbe top.

[@Clough42]

It hasn't hit yet. I could probably stand to shorten the cable to the overhead support arm.

[@danielminskey]

James...i am highly upset with you...you were supposed to release this video a 1 year and half ago when i built my plasma cutter. you will not be receiving any birthday or xmas cards from me. :) what a great informative video...this will help novices so much...also you are not supposed to use a water bed when plasma cutting aluminum...and can cause a hydrogen reaction..at least that is what i have read on the interwebs... keep up the great content...

[@Clough42]

I think the primary hydrogen risk with aluminum cutting is allowing it to end up in an enclosed storage tank.

[@Skyliner_369]

A spot welder? Do you mean a bunch of caps behind a pair of probes?

[@andarthome142]

I would have made another bend on de side of the Splash guard 45 degrees down so the water go down again, now it's splahing up again.👍👍😎

[@Clough42]

Yeah, I've been thinking about some kind of downward-facing deflector to prevent splashing and keep the sparks from reaching the edges of the table.

[@IRONMANMETALBILLDANKANIS]

I'm brand new to computers, I wish these videos slowed down and showed me where to look for stuff. I spent 40 minutes looking for this flange thing toward the beginning of the video and I cannot find it. This is so frustrating trying to do this stuff.

[@IRONMANMETALBILLDANKANIS]

I still can't find it

[@Bob_Adkins]

17.4?

[@FrancisoDoncona]

How’s that metic time coming along?

[@Clough42]

It works better in deep space, when you're tracking your shifts in cryo, waiting for the spiders to wake up.

[@Hossimo]

Now you just need the pen plotter mod.

[@donteeple6124]

As automated and digitized and exact as you do things I'm surprised that you havent modified your bender with a digital angle gauge display so you dont have to guess. And that would be a nice project to see you do!! Just saying.........

[@Clough42]

It has a gauge. I was talking to you and wasn't paying attention.

[@jamesrossmotors]

Thanks James. I have learnt so much from your posts. Have a drink on me

[@Clough42]

Thanks!

[@i_might_be_lying]

Oh, BTW, you might want to raise water level that water is almost touching the metal. That way water will actually catch most of the fumes. Saying this just in case (I assume you didn't raise water level because you didn't have torch cover ready).

[@Clough42]

Level full requires about 8 gallons. 5 gallons is easier to handle with a bucket.

[@Steelcrafted]

Hmmm it seems like doing CAM in Fusion is like overkill....does langmuir not provide a software package that will simply generate cut paths off a DXF file? We had a jd2 plasma table at work and we'd use sheetcam to generate cut paths and post process g-code...the Chinese fiber laser we have reads dxf's directly and handles all the g-code generation in the background...kinda like cut2d does with cnc routers....I have to think langmuir has a better solution for dxf's...

[@Clough42]

Fusion flattens the 3D model and accounts for the bend allowances. For a part this simple, it doesn't add much. For something more complex, and dimension-critical, it does.

[@Steelcrafted]

@@Clough42 right, but you can export a flat dxf from fusion that is is just as accurate as the 2d contour generated with fusion's cam package....we work exclusively with dxf's....activate flat pattern>create sketch>project>save dxf.... otherwise the dxf that fusion outputs will have bend lines and bend extent lines.

[@yax75]

How large is your workspace?

[@Clough42]

This plasma table is something like 24x30 inches. I don't remember exactly.

[@yax75]

@@Clough42 no your shop space.

[@Clough42]

@@yax75 ahh...2 bays of a 3-car garage.

[@yax75]

@@Clough42 thanks. I fully appreciate your channel, sometimes a bit long winded but I feel that is cause you want to truly explain a topic. Much like that sentence. Anyway love your content, please avoid the trolls and keep turning out the quality content

[@davidkarath6549]

Magnetic inclimeter for bending leg...

[@Clough42]

It has angle graduations. The trick, though. Is to look at them while bending.

[@BentoGambin]

You know, maybe, just maybe, the 1.55'' was actually 40 mm... LOL

[@Clough42]

Could be, but the screws are 1/4-20 and the clamp material is .499" thick, so it looks like an imperial design.

[@seeza]

How many rodeos have you attended?

[@ccga3359]

All this imperial/metric garbage. We should all stick to cubits. It's so much easier, the measurement betwixt the elbow and the middle finger. I am special as I'm missing the tip of my middle finger so I'm able to measure in both Metric Cubits and Imperial Cubits. It worked great until I built my shed in cubits... Turns out that I can't tell my ass from my elbow!

[@teaguewhite26]

You bloody imperialist, why must you insist on your measuring system? The rest of us have no problem using metrics. Jk'n of course I'm a bloody imperialist as well 😂