View Full Version : my 4' x 4' table build

02-20-2010, 08:23 PM
figured i'd jump in a post my latest project - a 4x4 plasma table.

i'm trying to incorporate everything i've learned with my router project, and ideas from all the projects posted here.

In late december i picked up the first component, a Hypertherm 1000 machine. This is the first time i've ever used a plasma cutter and its been alot of fun messing around

I debated on frame construction for a while, but decided to go outside for this. I worked with a local company that we do some business with who represents bosch / rexroth extruded aluminum.

From a rough sketch, they provided a finished drawing which they built this upon. I picked it up last week, and was blown away with the quality


the extra 60mm x 60mm piece will be my gantry member.

The table is laid out to support a 49" x 49" x 5" tray, which i am having fabricated from aluminum


I'm using some left over materials, included these 20mm linear rails


One thing i like about the frame, is that the levels are adjustable if things need to change in the design as i move forward

02-20-2010, 08:51 PM
Great looking start to build upon!:)

I'll be watching for your progress posts.

03-09-2010, 12:52 PM
progress is slow on this build, but hopefully will be picking up pace a bit

i just got my aluminum pan from the fabricators, which concludes the outside work. which means its up to me now :)

turned out nice

49" x 49" x 5"

My plan is to use 3" slats for work support, elevated from the bottom of the pan






03-10-2010, 07:03 AM
Is there any concern with galvanic corrosion in the water tank? I assume you will be cutting mostly carbon steel. Aluminum is often used as a sacrificial annode to protect steel from corrosion. I know you have a much greater surface area of aluminum in the tank but you will also have a lot of steel especially in the bath.

03-11-2010, 03:39 PM
thats a good question.. can anyone offer some input?

i know other people use aluminum so that you don't have an issue with the steel pan rusting.

03-12-2010, 09:21 PM
Nice work Multiplex!

I'm going to follow you.
Good Luck
It's interesting what BlackBird says about galvanic corrosion, can someone give us a wide explanation?

Jose -

07-21-2010, 10:37 PM
been focusing on this project more recently. couple photos to update the progress

i picked up the bladerunner controller from candcnc. super nice construction, and saved a ton of time


also picked up k2's 6" plasma z axis. again saving a ton of time


heres a pick of the X gantry. 20mm linear rails mounted on either side of a piece of Bosch extrusion. On top is some rack & pinon from motiontek


I'll be driving everything by steppers, run through a belt reduction. Not exactly sure of the ratio yet, but i can fit in 2, 3 or 4 to 1


the drives will be engages by air cylinders. I forget who's build i'm stealing this idea from, but i thought it was a great one. Allows easy movement of the axises when air is off

Hoping to finish up more of the machining this weekend, and maybe even starting to wire next week.

07-24-2010, 09:16 PM
OK got my air cylinder mounted up on the X axis - appears to work well. I'll have a valve to control the X axis and Y axis, with regulators


finished up the gantry side mounts, and it bolted right up to the main table :rainfro:



it will most likely be well over 100 degrees in the garage this weekend, so i've been hiding out doing other projects.

the build is probably on par of what would be needed for a router, so its a little over kill for a plasma table. however it should be able to handle some fast accelerations.. hope to find out this week :)

08-04-2010, 09:34 PM
been moving closer to the goal. Having bought the Bladerunner setup from CandCNC save sooooo much time its not funny. On my router i enjoyed building the control cabinet, etc but it must have eaten up a good week of my project time. Long story short, within about an hour of getting the gantry on the table i had the motion!

so far i've tested out 1000ipm without any issues. I'll most likely limit it to 800ipm to save some wear and tear. (so much faster than my router)

heres a pic of where i'm at now.. boy do i need to clean up the garage


side panel where i mounted the electronics, and computer


tonight i installed the torch control card inside the plasma cutter. didn't take much to splice in the torch start, and other required signals.



cut a little slot for the cable to exit the cabinet. this runs back to the main bladerunner control box.


next step is to mount the torch, and finish my water table. I also need to mount the limit switches and add some stops to prevent my gantry from flying off the bearings on a bad move

08-05-2010, 12:58 AM
What are you using a Hand or machine torch.

08-05-2010, 07:46 AM
i'm using the hand torch - wish i had the budget for machine torch at this point! maybe down the road

08-05-2010, 09:57 PM
spent a few hours tonight making the gantry stop blocks, which will also incorporate screws for adjusting the home position. Seperate switches on the left and right will allow me to 'square' up the gantry as needed


switches will mount on the gantry itself


08-07-2010, 07:50 AM
Hello Multiplex,

it looks all great! very nice.
I hope the machine will good working.
Good luck, i'am looking forward.


08-07-2010, 02:35 PM

getting closer every day. moved the table into its final home, and worked on the table slat holders. They are made from 2.5 x 2.5 aluminum tubing, 1/8 wall. They are cut 1.5" deep and have an angle on the top to make the slats curve. the slats will be 1/8" x 2" HRS



slat material should be here this week

08-09-2010, 12:55 PM
Looks great,I am looking for a good Plasma CNC setup and like what I see here. One question I see the controller box just below the water bed and an open vent in last photo. What are the chances of water or slag falling into the vent opening? Just a thought.

08-10-2010, 08:53 AM
great eye ron. somehow i missed that detail when i placed the control panel.

in retrospect, i've been designing some of the smaller details on the fly and then later regret making certain decisions. But overall pleased with how the machine is turning out. I've learned alot from my previous builds.

the water table does have an extra 2" lip that should prevent the water from flying around, although i probably will build an extra shield around the electronics

next hurdle is to find a good tank for storing the plasma quench. i have a bunch of 55 gallon drums, but the idea of cutting one down isn't attractive to me - but either is spending money on a nice tank :)

08-12-2010, 09:24 AM
installed my Y axis covers, and mounted up the torch.



calibrated my motors for distance too.

just waiting on the table slats and i need to make something to hang the torch wiring up above the table.

maybe cuts in the next few days?

12-16-2010, 09:22 AM
been awhile since i've updated :)

table is working well, and i seem to be getting a grasp of all the settings.

ended up bracing the Z axis in two places. One on the actual torch mount, and the other for the Z slide itself. With rapid moves, quick acceleration the torch was actually bouncing around (slightly)

of course i got to use the plasma cutter to make the one :)

I'm considering cross braces on the table frame too - as i still get some slight vibration on the torch.


the downside to winter - a frozen watertable in the garage. that might put a damper on things for a bit


luckily, i completed a big project just before the cold set in. railings for my front porch which have interchangable panels. there are 12 panels in all. The 6 in the front are the bird design, and the 6 side panels are slightly different / more formal which i don't have a pic of yet



04-07-2011, 01:32 AM
Hey Mulitplex

What a neat looking machine....very nice design...congratulations.


04-08-2011, 04:04 AM
Can you put some sort of anti freeze in?

Nice oval!