CNC Plasma 5x10

CNC Plasma Cutter
Plans
1500x3000 mm (5´x 10´)
1
Table of Contents
Introduction .............................................................................................................................................4
Frame .......................................................................................................................................................5
Frame assembly ....................................................................................................................................6
Frame Beams ........................................................................................................................................9
Rails ....................................................................................................................................................... 11
Rail assembly left ............................................................................................................................... 12
Rail Beam Drawings ........................................................................................................................... 13
Belt Protection Plate Drawing ........................................................................................................... 16
Table Assembly, step 1 ......................................................................................................................... 17
Side Wagons.......................................................................................................................................... 20
Side Wagon assembly left ................................................................................................................. 21
Sideplate left...................................................................................................................................... 23
Sideplate inner .................................................................................................................................. 24
Driveshaft .......................................................................................................................................... 25
Motor Tensioner ................................................................................................................................ 26
Distances ........................................................................................................................................... 27
AT5 Pulley 15 teeth, for 25 mm Belt ................................................................................................. 28
HTD3M Pulley, for 9 mm Belt ............................................................................................................ 29
X-Axis Wagon ........................................................................................................................................ 30
X-Axis Wagon assembly ..................................................................................................................... 31
Horizontal Plate for X-Axis Wagon .................................................................................................... 33
Vertical Plate for X-Axis Wagon ......................................................................................................... 34
Lower X-Axis Plate ............................................................................................................................. 35
Torch Breakaway .................................................................................................................................. 36
Torch Breakaway assembly ............................................................................................................... 37
Torch Breakaway Mount ................................................................................................................... 39
Torch Breakaway Plate ...................................................................................................................... 40
Torch Holder bottom ......................................................................................................................... 41
Torch Holder top ............................................................................................................................... 42
AT5 Belt Tensioner ................................................................................................................................ 43
AT5 Belt Tensioner assembly ............................................................................................................ 44
AT5 Belt Tensioner Plate ................................................................................................................... 45
Gantry Assembly ................................................................................................................................... 46
Gantry assembly, step 1 .................................................................................................................... 47
Aluminium Beam 80x80 .................................................................................................................... 49
2
Gantry L-Beams ................................................................................................................................. 50
Gantry Plates ..................................................................................................................................... 54
Gantry mounting................................................................................................................................... 55
Stand ..................................................................................................................................................... 57
Stand assembly .................................................................................................................................. 58
Stand Plate Drawings......................................................................................................................... 59
Table assembly, step 2 ......................................................................................................................... 60
Chain Support Beam Y ....................................................................................................................... 63
Table assembly, step 3 ......................................................................................................................... 64
CNC Plasma process .............................................................................................................................. 68
Bill of materials ..................................................................................................................................... 70
3
Introduction
After the design and build of my CNC plasma cutter table I decided to share my project in the form of
complete building plans. With the help of these plans a person who has some experience of
metalworking and welding should be able to build a CNC plasma table. To make the project a bit
simpler, some of the steps can be outsourced to mechanical workshops. All the drawings of the
custom parts are included and also a parts list with suggested suppliers. Many of the parts are
suitable for waterjet or laser cutting. For those parts, dxf cutting files is included which can be used
by a mechanical workshop with water or laser cutting capabilities.
The plans focus on the mechanical part of the table and the electronics part is only briefly covered.
There are many alternatives for how to design the electronics with motors, drivers, software etc. In
my build I used a plug-in kit from CandCNC with drivers, motors, cables and software(Mach3).
Another alternative is to buy all the electronics and motors separately, which requires some
knowledge on how to combine and assemble the parts.
Please feel free to make modification on your own build. If you find any errors or have suggestions
for making improvements on the plans, feel free to contact me. I hope that these planes can become
a good open source design of a plasma table. If you share your build these plans can be improved in
the future. A few of the ideas I have right now is to add a drawing of a watertable and making a more
thoroughly guide of the DIY electronics part. I simply bought a kit so I have only basic knowledge on
how to pick and assemble all the electronics from scratch. I made some basic instructions and tips for
the plasma cutting process which could be improved if someone have any good ideas. I have made
drawings and instructions for three sizes: 4’x4’(1250x1250mm), 4’x8’(1250x2500mm) and
5’x10’(1500x3000mm). If desired, I could also make plans for tables larger than 5’x10’ since the CAD
model can be updated by changing the parameters controlling the size.
Regarding the rigidity of the table, I would not recommend cutting material with a higher weight
than 400 kg. Since I haven’t tried the limits it may be possible to use a heavier plate, but it can create
problems with the motion of the gantry due to deformation.
The table could probably be used as a milling machine, but it may require more stable belts, bearings
and different motors, especially for the larger versions of the table. The gearing after the motors is
also designed for plasma cutting, since the cutting of thin sheet metal requires high speed.
I take no responsibility for accidents caused when building and using this machine. I recommend
using a high quality plasma cutter and follow the manufacturers recommendations for safety. Use
correct safety goggles. Make sure to have a very good ventilation or an extraction fan to remove the
fumes created during cutting. The table can be equipped with a downdraft chute or water table to
have an effective collection of dust and smoke. Also make sure that the sparks don’t create a fire.
Good luck with your build!
Best regards
Peter
peter89axelsson@hotmail.com
4
Frame
Cut and drill all the beams required for the frame, see drawings on page 9-10. Make sure to have a
level surface to build on. The frame should only be tack welded until it is completely assembled. Start
with the bottom beams and make sure they are squared by measuring the diagonals. Attach the
vertical beams and then the top horizontal beams. It is good to use a 3-axis weld clamp for the joints.
When the frame has the correct dimensions and everything is squared and levelled, the triangulation
beams can be attached.
To minimize warping of the frame, the final welding should be done as symmetrically as possible.
When one joint is welded, the joint on the opposite side should be welded after that. When the
joints are being fully welded the frame tends to warp and shrink a little bit. Make some measuring
during the welding to make sure everything is squared. However, if the frame is not perfect it will be
possible to compensate for that when mounting the rails. If you intend to build a water pan, don’t
weld the “BEAM_L_SUPPORT_40x40x3” [10] to the frame. Paint the frame after welding. When
painting the frame, make sure that “GROUND_CONNECTOR” [98] have electrical contact with
“BEAM_TOP_MIDDLE_Y” [8]. Also make sure that “BEAM_TOP_MIDDLE_Y” [8], will have electrical
contact with “MATERIAL_SUPPORT_50X3” [17] (mounted in a later stage), so it can make ground
contact with the material being cut.
5
Frame Assembly
7 8 3 6 130 131 5
3
10
4
3
5 2
7
1
98
650
600
Z
Y
X 6 2 3 1
6
Frame Assembly
100 x31 100 x31

55
100 x31
155 155
WHEN PAINTING THE FRAME, MAKE SURE THAT "GROUND_CONNECTOR"[98]

HAVE ELECTRICAL CONTACT WITH "BEAM_TOP_MIDDLE_Y"[8]
MIDDLE L-SUPPORTS IN THE OPPOSITE

DIRECTION OF THE OUTER L-SUPPORTS
7
Frame Assembly
No Part Name Description Qty

1 BEAM_BOTTOM_Y Bottom Beam Y 50x50x3 2
2 BEAM_BOTTOM_X Bottom Beam X 50x50x3 2
3 BEAM_CORNER Vertical Corner Beam 50x50x3 4
4 BEAM_TOP_Y Top Beam Y 50x50x3 2
5 BEAM_TOP_X Top Beam X 50x50x3 2
6 BEAM_TRIANGULATION_X Triangulation Beam X 30x30x2 2
7 BEAM_TRIANGULATION_Y Triangulation Beam Y 30x30x2 6
8 BEAM_TOP_MIDDLE_Y Top Middle Beam Y 50x50x3 1
9 BEAM_VERTICAL_MIDDLE Middle Vertical Beam 50x50x3 4
10 BEAM_L_SUPPORT_40X40X3 L Profile Support 40x40x3 96
98 GROUND_CONNECTOR Ground Connecting Cable 250 1
mm, Cable Lugs with 8 mm hole
130 M8X110_BOLT M8x110 Bolt, Hexagon Head 2
131 ISO4032-M8-6 M8 Nut 2
8
Frame Beams
3450
NO MTRL. SECTION TOT. QTY.

1 STEEL 50x50x3 2
3350

4 STEEL 50x50x3 2
1650

2 STEEL 50x50x3 2 25
3
1650 40
3
825
8.5 THRU 25
NO MTRL. SECTION TOT. QTY. NO MTRL. SECTION TOT. QTY.
5 STEEL 50x50x3 2 10 STEEL L 40x40x3 42
9
Frame Beams 750 25
10.5 THRU 600

25
3 STEEL 50x50x3 4 9 STEEL 50x50x3 4
25 3450 25
8.5 THRU 8.5 THRU
25 25
8 STEEL 50x50x3 1
1238
1773
22°
29°
68°
61° 61°
68°
29°
22°

7 STEEL 30x30x2 6 6 STEEL 30x30x2 2
10
Rails
Cut and drill the beams required for the rails, see drawings on page 12-15. If you are not able to drill
the holes with high accuracy, the holes in “BEAM_RAIL_20X3” [12] can be drilled larger to be able to
adjust the rail to correct position. Weld the brackets [13] and [14] in place. The long protection plate
only needs welding at a few places along the rail, too much welding may cause warping on the rail
beam. Paint the parts after welding and before before bolting them together. It may be convenient
to make a small jig to position “BEAM_RAIL_20X3” [12] at the correct height.
11
WELD
Rail assembly left DETAIL B
INTERMITTENT
52
- - - - - -
12 11
12
20
118 6
WELD
14 SEE DETAIL A
DETAIL A 45
ASSEMBLYS OF LEFT AND RIGHT

RAIL ARE MIRRORED
SEE DETAIL B 13

11 BEAM_RAIL_SUPPORT Beam for Rail Support 50x50x3 1
WELD 12 BEAM_RAIL_20X3 Rail Beam 20x3 2
13 BELT_FASTENER_Y Bracket for Y Belt 1
14 BEAM_BELT_TENSION_Y_LEFT Bracket for Left Belt Tension 1
45 BELT_PROTECTION Plate for Belt Protection 1
118 ISO4017-M6X12-8_8 M6x12 Bolt, Hexagon Head 36
12
Rail Beam Drawings
SEE DETAIL C
3450
200 x17
SEE DETAIL D
25 7 NO MTRL. SECTION TOT. QTY. 25
11 STEEL 50x50x3 2
25 25
5 x36
M6 THREAD TAPPING
10.5 10.5
THRU THRU
DETAIL C 7 DETAIL D
E
SCALE 1:1
SEE DETAIL
SCALE 1:1
3450
200 x17
25 DETAIL ESCALE 1:1

12 STEEL 20x3 4
7 6.4 x18
IF IT IS NOT POSSIBLE TO POSITION THE HOLES WITH HIGH ACCURACY, THE
HOLES CAN BE MADE LARGER TO BE ABLE TO ADJUST THE RAIL WHEN MOUNTING
13
Rail Beam Drawings
HOLE PATTERN MAY VARY WITH DIFFERENT BELT CLAMPS
32 9
12.5
25
4.2 X4
50 M5 THREAD TAPPING

10 13 STEEL 50x50x3 2
14.4
14
Rail Beam Drawings
14.4
FOR LEFT RAIL
10
65 8.5

14.3
14 STEEL 50x50x3 1
25
FOR RIGHT RAIL

15 STEEL 50x50x3 1
15
Belt Protection Plate Drawing
3346
80 DXF FILES FOR CUTTING INCLUDED
NO MTRL. THICKNESS TOT. QTY.

45 STEEL 2 MM 2
16
Table assembly, step 1
When bolting the rails to the frame, make sure that the rails are levelled, parallel and have the same
height. Adjust with shims if necessary. Drill holes in the bottom of the frame for attaching the caster
wheels. Lastly, mount all the “MATERIAL_SUPPORT_50x3” [17] beams.
17
137
135 137 138 137 136
138
22
21
131
151
127
131
151
MAKE SURE THAT THE RAILS ARE LEVELLED,

PARALLEL AND HAVE THE SAME HEIGHT. 127
ADJUST WITH SHIMS IF NECESSARY. 18

17 MATERIAL_SUPPORT_50X3 Material Support Beam 50x3, 1750 mm 32
21 RAIL_LEFT Left Rail for Y-Axis 1
22 RAIL_RIGHT Right Rail for Y-axis 1
127 ISO4762-M8X28-8_8 M8x28 Bolt, Allen Head 8
131 ISO4032-M8-6 M8 Nut 8
135 M10X110_BOLT M10x110 Bolt 2
136 THREADED_ROD_M10X180 M10x180 Threaded Rod 2
137 ISO4032-M10-6 M10 Nut 6
138 M10_WASHER_2MM M10 Washer, 2 mm Thickness 4
151 CASTER_WHEEL_PIVOT Pivoting Caster Wheel 4
19
Side Wagons
Manufacture the parts required for the Side Wagons, see drawings on page 23-29. Dxf cutting files is
included for the parts made from plates. Assemble the two Side Wagons according to the drawing at
page 21. “MOTOR_TENSIONER” [80] can be welded together when assembling the Side Wagons,
using the other parts as a welding jig. Paint the motor tensioner after welding. Apply some tension
on the step motor belt. The drawing shows the left Side Wagon. Assemble the right Side Wagon as a
mirror of the left. The only difference on the right is that the big plate doesn’t have a bracket for the
belt tensioner.
20
Side Wagon assembly left
124 133 126 30
36 64
123 69
80
134
117
70
133
93
133
116
71
66
73
60
68
140 74 63 132 132 67 61 65 32 68 129
ASSEMBLY OF RIGHT SIDE WAGON IS MIRRORED TO LEFT SIDE WAGON.
21
Side Wagon assembly left

30 SIDEPLATE_LEFT Sideplate Left 1
32 SIDEPLATE_INNER Sideplate Inner 1
36 TENSION_BLOCK Block for Step Motor Tensioner 1
60 DRIVESHAFT Driveshaft for Belts 1
61 DISTANCE_40MM Distance 40 mm 1
65 DISTANCE_3_POINT_8_MM Distance 3.8 mm 2
66 STOP_RING Stop Ring for Driveshaft 1
67 BEARING_8X24X8 Sealed Bearing 8x24x8 mm 6
69 V GROVE BEARING V Groove Bearing 3/8" 3
70 HTD3M_16T HTD3M Pulley 16 Teeth, for 9 mm Belt 1
71 HTD3M_48T HTD3M Pulley 48 Teeth 14 mm 1
bore, for 9 mm Belt
73 HTD3M_BELT_110T HTD 330-3M Belt, 110 Teeth 9 mm 1
74 PULLEY_AT5_15T AT5 Pulley 15 Teeth 10 mm 1
bore, for 25 mm Belt
80 MOTOR_TENSIONER Step Motor Tensioner 1
93 STEPMOTOR_NEMA23 Nema 23 Step Motor 1
117 ISO4032-M5-6 M5 Nut 4
126 ISO4032-M6-6 M6 Nut 4
132 WASHER_M8_1POINT6MM M8 Washer, 1.6 mm Thickness 4
133 HEXSOCKSCREW-3_8-16X1_5 3/8"-16x1.5" Bolt 3
134 HEXNUT-3_8-16 3/8"-16 Nut 3
140 SPRING_PIN_3X18 Spring Pin 3x18, for 3 mm hole 1
22
Sideplate left
DXF FILES FOR CUTTING INCLUDED,
BEARING SEAT NEEDS MACHINING
250
268
A
+0.03
26
0 22
6.8 x3 A
M8 THREAD TAPPING 10
SECTION A-A
RIGHT SIDE WAGON IS MIRRORED TO THE LEFT SIDE WAGON,

EXCEPT FOR THE BELT TENSION BRACKET AT THE TOP.

30 ALU 10 MM 1
23
Driveshaft
26 70
14.6
0 0
14 10
-0.008 -0.008
+0.12
3 H12
0
HOLE FOR SPRING PIN, PREFERABLY
DRILLED TOGETHER WITH AT5 PULLEY
FOR A GOOD FIT.
NO MTRL. TOT. QTY.

60 STEEL 3
24
Sideplate inner
A
8
24 24
22
+0.03
26
0
14.5
8 x3 82.5
55
(40.5)
10
70
A SECTION A-A
DXF FILES FOR CUTTING INCLUDED, BEARING SEAT NEEDS MACHINING

32 ALU 10 MM 2
25
Motor Tensioner
126 44
WELD
USE SIDE WAGON AS A WELDING JIG
25
40
5.5 x2 5
15
6.5 6.5
60

44 STEEL 2 MM 3
DXF FILES FOR CUTTING INCLUDED

44 TENSION_PLATE Plate for Motor Tensioner 1
126 ISO4032-M6-6 M6 Nut 2
26
Distances
NO MTRL. TOT. QTY.

9.8 14
64 STEEL 6
NO MTRL. TOT. QTY.

8.5 12
63 STEEL 6
9
NO MTRL. TOT. QTY.

8.5 12
65 STEEL 6
3.8
12 8.5
NO MTRL. TOT. QTY.
61 STEEL 3
40
NO MTRL. TOT. QTY.

18 8.5
62 STEEL 2
42.5
27
AT5 Pulley 15 Teeth, for 25 mm Belt
+0.12
3 H12
0
HOLE FOR SPRING PIN, PREFERABLY DRILLED
TOGETHER WITH DRIVESHAFT FOR GOOD FIT.
3.5
+0.018
10 H7
0
NO TOT. QTY.
74 3
28
HTD3M Pulley 48 Teeth, for 9 mm Belt
+0.018
14 H7
0
2 CLAMPING SCREWS AT MINIMUM
NO TOT. QTY.
71 3
29
X-axis Wagon
Manufacture the parts required for the X-axis Wagon, see drawings on page 33-35. Dxf cutting files is
included for the parts made from plates. Assemble the X-axis Wagon according to the drawing at
page 31. Apply some tension on the step motor belt
30
X-Axis Wagon assembly
115 60 71 72 117 80
33 123
36
120
125
112
126
68
34 70
78 61
63
93
132
116
132
116
67
116
65 140 35 74 66 68 129 114

31
X-Axis Wagon assembly

33 X_AXIS_PLATE_HORIZONTAL Horizontal Plate for X-Axis Wagon 1
34 X_AXIS_PLATE_VERTICAL Vertical Plate for X-Axis Wagon 1
35 X_AXIS_PLATE_LOWER Plate below X-Axis Driveshaft 1
36 TENSION_BLOCK Block for Step Motor Tensioner 1
60 DRIVESHAFT Driveshaft for Belts 1
65 DISTANCE_3_POINT_8_MM Distance 3.8 mm 2
66 STOP_RING Stop Ring for Driveshaft 1
70 HTD3M_16T HTD3M Pulley 16 Teeth, for 9 mm Belt 1
71 HTD3M_48T HTD3M Pulley 48 Teeth 14 mm 1
bore, for 9 mm Belt
72 HTD3M_BELT_90T HTD 270-3M Belt, 90 Teeth 9mm 1
74 PULLEY_AT5_15T AT5 Pulley 15 Teeth 10 mm 1
bore, for 25 mm Belt
78 LINEAR_BEARING_TBR16 TBR16UU Linear Bearing 4
80 MOTOR_TENSIONER Step Motor Tensioner 1
93 STEPMOTOR_NEMA23 Nema 23 Step Motor 1
117 ISO4032-M5-6 M5 Nut 4
126 ISO4032-M6-6 M6 Nut 4
132 WASHER_M8_1POINT6MM M8 Washer, 1.6 mm Thickness 4
140 SPRING_PIN_3X18 Spring Pin 3x18, for 3 mm hole 1
32
Horizontal Plate for X-Axis Wagon DXF FILES FOR CUTTING INCLUDED,
SECTION A-A BEARING SEAT(SECTION A-A) AND NUT
POCKET(SECTION B-B) NEEDS MACHINING.
10
15
8
292.8
6.8 x3 +0.03
M8 THREAD TAPPING 26
0
20
A A 154
5 x4
B B M6 THREAD TAPPING 105 160
22
12
5 x2
M6 THREAD TAPPING
13 146 55
15
5 6
10 NO MTRL. THICKNESS TOT. QTY.
33 ALU 10 MM 1
SECTION B-B 33
Lower X-Axis Plate
+0.03
22 26
0
35
70
15
8 x3
50 8
A SECTION A-A
DXF FILES FOR CUTTING INCLUDED,

BEARING SEAT NEEDS MACHINING.

35 ALU 10 MM 1
34
Vertical Plate for X-Axis Wagon DXF FILES FOR CUTTING INCLUDED
160
154
105
55 (6)
6
5
6 x4
MAKE ADDITIONAL HOLES FOR ATTACHING THE Z-AXIS
5 x8
136.2
6 6
50 50
30 30
6 NO MTRL. THICKNESS TOT. QTY. 6

34 ALU 6 MM 1
35
Torch Breakaway
Manufacture the parts required for the Torch Breakaway, see drawings on page 39-42. Dxf-files for
cutting is included. The limit switch function is to activate a stop if the torch breaks away. The
number of magnets can be adjusted to change the force required to break the torch off. The torch
holders is designed for Hypertherm T45m machine torch, adjust them if you plan to use another
plasma torch. If a hand torch is used, the top torch holder is not needed.
36
Torch Breakaway assembly THE NUMBER OF MAGNETS
CAN BE ADJUSTED TO CHANGE
41 94 110 117 155 113 42 THE BREAKAWAY FORCE
GLUE
GLUE
121 40 97 122 126 39 119

37
Torch Breakaway assembly

39 TORCHPLATE Torch Breakaway Plate 1
40 TORCH_HOLDER_BOTTOM Torch Holder Bottom 1
41 TORCH_HOLDER_TOP Torch Holder Top 1
42 TORCH_BREAKAWAY_MOUNT Torch Breakaway Mount 1
94 LIMIT SWITCH BESAR Limit Switch NO/NC, Long Arm 1
97 LINEAR_LASER Linear Laser, 3 Volts 2
113 ISO10642-M5X16-8_8 M5x16 Bolt Countersunk 4
117 ISO4032-M5-6 M5 Nut 4
126 ISO4032-M6-6 M6 Nut 4
155 MAGNET_20X5 Torch Breakaway Magnet 20x5 4
38
Torch Breakaway Mount A
80
15 50 3
35
90° x4
130
70
3 x4
PILOT HOLE FOR
A SECTION A-A
COUNTERSUNK DRILL DXF FILES FOR CUTTING INCLUDED

MAKE ADDITIONAL HOLES FOR
ATTACHMENT ON THE Z-AXIS 42 STEEL 4 MM 1
39
Torch Breakaway Plate
5 6 x4
5.5
5 x4
M6 THREAD TAPPING
5.5 5.5
120
5.5 95
5.5
60
5
6 x4 25
9
15
40
65
39 ALU 6 MM 1
71
80
40
Torch Holder bottom
35
HOLE FOR HYPERTHERM T45M MACHINE TORCH,
ADJUST HOLE SIZE FOR YOUR DESIRED PLASMA TORCH
R6 x2
6
(9)
13 18.1
5
5
M6 M6
9
40 DXF FILES FOR CUTTING INCLUDED
71
80

40 ALU 10 MM 1
41
Torch Holder top
IF A HAND TORCH IS USED, THIS PART IS NOT NEEDED
35
HOLE FOR HYPERTHERM T45M MACHINE TORCH,
ADJUST HOLE SIZE FOR YOUR DESIRED PLASMA TORCH.
6
(9)
M3
13
5 2.5 18.1
M6
5
9 M6
40
71
80

41 ALU 10 MM 1
42
AT5 Belt Tensioner
Manufacture the steel plate, dxf file is included. Weld the bolt on to the edge of the plate and make
sure it is aligned and parallel with the plate. Paint the Belt Tensioner after welding and attach the
belt clamp with the M5 bolts.
43
AT5 Belt Tensioner
112
43 SEE DETAIL A
76 128
22
1.5
WELD
117
DETAIL A SCALE 2:1

43 BELT_TENSION_PLATE AT5 Belt Tensioner Plate 1
76 BELT_CLAMP_AT5 AT5 Belt Clamp 1
117 ISO4032-M5-6 M5 Nut 4
44
AT5 Belt Tensioner Plate
50
5 x4 25
6 8.5
32
44

43 STEEL 4 MM 3
45
Gantry assembly
Manufacture the beams and cut the rails required for the gantry, see drawings on page 48-49 and 53.
Dxf cutting files is included for the parts made from plates.
Step 1: Attach the left Side Wagon to the gantry beam. Make sure that the Side Wagon is
perpendicular to the gantry beam, adjust with shims if necessary. Attach all the other parts to the
gantry beam. Don’t tighten all of the rail bolts, it may need adjustment in next step.
Step 2: Slide the X-axis Wagon on to the rails and mount the cable chain holder on the X-axis Wagon.
If the X-axis Wagon don’t fit or it slides with high friction, adjust the rail. Tighten the rail bolts. Mount
the cable chain. Attach the AT5 belt and the belt tensioner. Pull the belt through the X-axis drive
pulley and bearings. If necessary, make holes on the Z-axis to be able to mount it to the X-axis
Wagon. Also make holes for connecting the Torch Breakaway Mount. Mount the Z-axis, Torch
Breakaway and torch on the X-axis Wagon. Glue the limit switches to the beam at a point where they
are activated 10 mm before the X-axis Wagon hits its mechanical limit.
Step 3: Mount the belt fastener bracket and attach the belt. Apply some tension on the AT5 belt.
When hand force is applied on the X-axis Wagon(with the drive shaft locked), the belt tension will
decrease on one side. If that side still have some tension when hand force is applied, the tension is
high enough. When the table is finished, you may have problem with the belt climbing over the
flange of the pulley. That problem can be solved by increasing the tension and check that the
alignment of the pulleys and bearings are correct. On my build I had to remove the flanges on the
pulley for the X-axis Wagon and one of the Side Wagons to stop the belt from climbing over the
flange and damage the belt over time.
Steps for troubleshooting of belt climbing:
1. Use proper tension as described above

2. Check alignment of belt, belt pulley and bearings
3. Increase tension of belt
4. Remove flanges if the problem is left. The belt may become non-centered over the pulleys
without flanges, but the table will still function properly. The belt wear may be slightly higher
without flanges.
46
Gantry assembly, step 1
127 111 19 77
111
153
85
MAKE SURE THAT THE SIDEWAGON IS PERPENDICULAR TO 117

THE GANTRY BEAM, ADJUST WITH SHIMS IF NECESSARY
111
77 111 114 18 114
47

18 BEAM_ALU_8080 Aluminium Beam 80x80 1
19 BEAM_CHAIN_SUPPORT_X L Profile 20x2, supporting Cable Chain X 1
77 SUPPORTED_AXLE_TBR16 Supported Axle TBR16 2
85 SIDEWAGON_LEFT Left Sidewagon 1
117 ISO4032-M5-6 M5 Nut 1
153 CHAIN_END_1 Cable Chain End, type 1 1
48
Aluminium Beam 80x80
B
1878
A 150 x12 45
A B
C
INSTEAD OF USING THREADED HOLES AND BOLTS, RAILS AND

C 12
CHAIN SUPPORT CAN ALSO BE ATTACHED WITH SELF DRILLING
SCREWS ON BEAMS WITH THINNER WALL THICKNESS.
865 x2
37
12 M5 x3 6.5
4.2 x3 M5 x13 40
M5 x13
4.2 x13 8
4.2 x13
M5 x13
8 4.2 x13
7
40 37
SECTION A-A SCALE 1:2
6.5 SECTION B-BSCALE 1:2
SECTION C-C
4.2 x13 M8 THREAD TAPPING ON
SCALE 1:2
M5 x13 BEAM ENDS, 20 MM DEEP 49

Gantry L-Beams
5 5
12 13
5

19 ALU 20x20x2 1 865 x2 12
45
9.5
5 x2
NO MTRL. SECTION TOT. QTY

20 ALU 20x20x2 2
50
131 79 75 152 94 120 37 83

117 117 112
94
154
20
111
91
82 42 81 94 94
51

20 BEAM_CHAIN_BRACKET L profile 20x2, Cable Chain attachment 1
37 CABLE_CHAIN_HOLDER_X Cable Chain Holder for X wagon 1
42 TORCH_BREAKAWAY_MOUNT Torch Breakaway Mount 1
75 BELT_AT5 AT5 belt, approx. 1900 mm 1
79 BELT_TENSIONER AT5 Belt Tensioner 1
81 Z_AXIS Z-axis Assembly 1
82 TORCH_BREAKAWAY Torch Breakaway Assembly 1
83 X_AXIS X-axis Wagon Assembly 1
91 TORCH_T45M T45m Machine Torch 1
117 ISO4032-M5-6 M5 Nut 4
131 ISO4032-M8-6 M8 Nut 2
152 CHAIN_LINK Cable Chain, approx. 2100 mm 1
52
117 112 117 38 117 114
20
129
154
111
76 141 62

20 BEAM_CHAIN_BRACKET L profile 20x2, Cable Chain 1
attachment
38 BELT_FASTENER_X Fastener for X Belt and Chain 1
62 DISTANCE_42POINT5MM Distance 42,5 mm 2
117 ISO4032-M5-6 M5 Nut 8
141 T_SLOT_NUT_M8 M8 T-slot Nut, size 8 2
53
Gantry Plates
68
(12)
9 129.5
5 x2 26
20
20
18
26 (12)
8.5 25
190.5 32 5 x4
210
160
8.5 x2
81.6
60
6.5 x2 13 20
22.5
6
5 42
25
NO MTRL. THICKNESS TOT. QTY. 38 ALU 6MM 1
37 ALU 6MM 1
54
Gantry mounting
Place the gantry on the left rail and attach the right Side Wagon to the gantry beam. Make sure that
the right Side Wagon is perpendicular to the gantry beam, adjust with shims if necessary. Make sure
that the V Groove Bearings are aligned with the rail, adjust with shims if necessary. Push the bottom
V Groove Bearing upwards and tighten the nut. Slide the gantry to both ends and check for smooth
motion. If there is a resistance at some point on the rail, it may be necessary to adjust the bottom V
groove bearing slightly downwards. All upper V Groove Bearings should have contact with the rails at
all times. Adjust the rail if necessary. Glue the limit switch to the right Side Wagon.
55
Gantry mounting SEE DETAIL A
MAKE SURE THAT THE SIDEWAGON IS
PERPENDICUAR TO THE GANTRY BEAM
AND THAT THE V GROOVE BEARINGS
ALIGN WITH THE RAIL. ADJUST WITH
SHIMS IF NECESSARY.
86
127
DETAIL A
SCALE 1:4
GLUE
PUSH THE V GROOVE BEARING UPWARDS
TO THE RAIL AND TIGHTEN THE NUT

86 SIDEWAGON_RIGHT Right Sidewagon 1
94 LIMIT SWITCH BESAR Limit Switch NO/NC, Long Arm 1 94
127 ISO4762-M8X28-8_8 M8x28 Bolt, Allen Head 4 56
Stand
Assemble the stand later if you intend to cut the plates with the finished plasma cutter. Weld the
plates together according to the drawing. It is enough with intermittent welds along the connecting
edges. Paint the stand.
57
Stand assembly 46
50
51
650
47
52
48 50 75
49
46 PLATE_STAND_1 Plate for Computer Stand 1
50 PLATE_STAND_BOTTOM Plate for Computer Stand 1
47 PLATE_STAND_LEFT Plate for Computer Stand 1
48 PLATE_STAND_MIDDLE Plate for Computer Stand 1
49 PLATE_STAND_RIGHT Plate for Computer Stand 1
51 PLATE_STAND_TOP Plate for Computer Stand 1
52 PLATE_STAND_TOP_SUPPORT Plate for Computer Stand 1
58
Stand Plate Drawings 60
400
175
HOLES ARE FOR BUCKLE STRAPS, POSITION THEM

FOR YOUR DESIRED PLASMA CUTTER AND COMPUTER
25
900
330
25
410
50 60
410
50
270 100
10 10
1600 1650
1750 R35
350 350 350
22 x2
R65 R65
720
585
800 127 800 800
50
HOLE FOR AIR SUPPLY TO
POWERMAX 45 PLASMA CUTTER
65
2MM STEEL. DXF FILES FOR
240 CUTTING INCLUDED, MAY BE
CUT WITH THE PLASMA CUTTER
175 175 110 59
Mount the stand with self-drilling screws. The stand can also be mounted later if you intend to cut
the plates for the stand with the functioning plasma cutter. Attach the limit switch, the Cable chain
support and the cable chain. Attach the AT5 belt and the belt tensioner. Pull the belt through the
Side Wagons drive pulleys and bearings. When the table is finished, you may have problem with the
belt climbing over the flange of the pulley. The solution is described in the gantry assembly.
60
SEE DETAIL C DETAIL C SCALE 29:192
131 137
79
75
75
112
DETAIL B SCALE 19:96
152
97
76
53
SEE DETAIL B
139 111 137 94 16 153 117
61

16 BEAM_CHAIN_SUPPORT_Y Chain Support Beam Y 1
53 STAND Stand/Table for Computer etc. 1
75 BELT_AT5 AT5 Belt, approx. 3450 mm 2
79 BELT_TENSIONER AT5 Belt Tensioner 2
117 ISO4032-M5-6 M5 Nut 1
131 ISO4032-M8-6 M8 Nut 4
137 ISO4032-M10-6 M10 Nut 4
139 DRILLING_SCREW_4_8X13 Self Drilling Screw 4,8x13 6
152 CHAIN_LINK Cable Chain, approx. 3700 mm 1
62
Chain Support Beam Y
90 5.5
20 3450
25 10.5 x2 25
25 25
NO MTRL. Section TOT. QTY.

16 STEEL L 40x3 1
63
Attach the electronics, cables, computer and plasma cutter. There are many alternatives for the CNC
electronics. The easiest solution is to buy a kit with motors and driver electronics which simply plugs
in to a PC. Make sure to pick a kit that can handle the gantry weight, which is around 40 kg(excluding
step motors). These kits can be bought from:
- http://www.candcnc.com
- http://www.cncrouterparts.com
- http://www.flashcutcnc.com
- http://www.procutcnc.com
Personally I use a Bladerunner kit(100lb gantry, 620 oz.in steppers) from CandCNC and a Hypertherm
Powermax 45 plasma cutter, which is a very good combination in my opinion. When choosing a
electronics kit, decide if you need THC(Torch Height Control) or not. The THC can keep the cutting
height constant when the material height changes due to warping. Without THC, the warping can be
a problem if no water table is used. Thinner plates have more warping than thicker plates. If you will
cut a lot of thinner material (<3 mm) and don’t intend to use a water table, I would recommend a
THC. Follow the included manual to connect and set up the electronics kit.
Gear ratio: The relation between the step motor turning and the motion of the X- and Y-axis is 25
mm per revolution. This have to be set in the CNC control software. For step motors with 1.8° per
360
step, it means that the setting should be = 8 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠/𝑚𝑚𝑚𝑚. The Z-axis setting depend on the gear
1.8∗25
ratio of the Z-axis. Verify the settings by moving the axes with the CNC control software and measure
the distance travelled. The settings may need some adjustment due to the tension of the belts.
Plasma Cutter: Choose a plasma cutter for the maximum material thickness you intend to cut. The
cutting capacity can be different for different materials. When choosing the size of the plasma cutter,
also be aware of the duty cycle. The maximum amperage of a plasma cutter can not be used
continuously. If you would like to be able to cut large jobs without pauses in the program, the
maximum amperage have to be more than the amperage required to cut your desired thickness.
DIY Electronics: If you decide to build the electronics from scratch there is a lot of options. The basic
components needed is:
- Step motors (Nema 23, 3 Nm minimum)

- Step motor drivers
- Breakout board/Motion control board (choose one that works with the CNC control
software)
- Relay board for controlling the torch
- Power supply
- Torch Height Control (optional, good when cutting thin material which tends to warp)
- PC
- CNC control software, Mach 3/Mach 4 and LinuxCNC is the most popular
Kits with step motors, drivers, breakout board and power supply:
- http://www.cncrouterparts.com/4-drive-diy-nema-23-electronics-kit-p-75.html
- https://www.cnc4you.co.uk/Stepper-Motor/Nema23-4Nm/Stepper-Motor-Kit-4Nm-x-4-Axis-
Nema23
- https://buildyourcnc.com/Item/electronicsAndMotors-4axis-425-elcombo
64
- https://www.ebay.com/itm/4Axis-Nema23-stepper-motor-425oz-DUAL-SHAFT-Driver-
DM542A-CNC-Longs-Motor/200998727736?hash=item2ecc753038:g:tOQAAOSwi6Nbdj6g
- https://www.ebay.com/itm/EU-FREE-Ship-4axis-Nema23-stepper-motor-425oz-in-single-
Drivers-DM542A-CNC-
kit/162304707881?epid=2242102865&hash=item25ca1d4d29:g:lmUAAOSwYSBbW9Dd
Make sure to choose step motors that can handle the gantry weight, 3Nm(425 oz.in) at minimum. If
the step motors are too weak, you may have to lower the maximum acceleration settings in the CNC
software. Lower acceleration will affect the cut quality slightly on thinner materials. The Z-axis can
use a less powerful step motor.
Sources for information on CNC electronics:
- https://www.cnccookbook.com/diy-cnc-machine-types-build/#chapter5
- http://www.buildyourcnc.com
- http://www.themakersguide.com/making-cnc-milling-machine-cnc-electronics
- http://www.cncroutersource.com/cnc-electronics.html
- http://www.cnczone.com
Most of the information on CNC electronics is directed to milling machines but it still applies for CNC
plasma cutters. The main differences is that a CNC plasma uses a Z touch off to zero the Z-axis at the
material surface, and a Torch Height Control (THC) to keep the correct cutting height.
The Z touch off is simply a switch that activates when the plasma torch makes contact with the
material. It can be mechanically implemented with a floating torch holder or electronically detecting
a contact between the torch and the material. This is used for re-zeroing of the torch before a new
cut.
The THC keeps the cutting height correct even if the material warps. When the plasma machine is
cutting, the current of the arc is constant. Since the current is constant, the voltage will vary with the
distance between the torch and the material. The voltage required to create an arc with a specific
current is proportional to the distance between the torch and the material. This phenomenon makes
the voltage a good measurement of the cutting height, which is an important parameter in plasma
cutting. The THC unit measures the voltage, compares it to the pre-set value and gives up/down
signals to the CNC control software via the breakout board/motion controller. The CNC control
software uses the signals to control the Z-axis. There are also some THC units that can control the Z-
axis independently of the CNC electronics and software, for example the Proma SD THC. Make sure
that you choose a THC unit that works with your breakout board/motion controller and CNC control
software.
Example of THC units:
- http://proma-elektronika.com/index.php/en/products/thc-torch-height-control/compact-
thc-150
- https://www.poscope.com/product/plasmasens/
- https://www.pricecnc.com/product-page/avhc10
- https://www.ebay.com/itm/HP105-Torch-Height-Controller-THC-for-CNC-Plasma-Arc-
Voltage-Cutting-
Machine/282362523035?epid=1183939399&hash=item41be1e2d9b:g:bT8AAOSwB-1YpSQo
65
101 103
95
96
131
130
90
ATTACH THE M8X110 BOLT[130] TO 100 102 92 99

THE GROUND CONNECTOR[98].
66

90 POWERMAX_45 Plasma Cutter 1
92 CNC_ELECTRONICS CNC Control Electronics 1
95 PUSH_SWITCH Push Switch, Momentary On 1
96 EMERGENCY_STOP Emergency Stop Switch NO/NC 1
99 CABLES Cables for 1
Plasma/Electronics. Straps,
Connectors, Shrink Tubing etc.
100 COMPUTER Computer 1
101 BENQ 21.5'' LED MONITOR Computer Monitor 1
102 KEYBOARD Keyboard 1
103 MOUSE Mouse 1
130 M8X110_BOLT M8x110 Bolt, Hexagon Head 1
131 ISO4032-M8-6 M8 Nut 2
67
CNC Plasma process
The following chart describes the process of CNC plasma cutting:
CAD program CAM program CNC Control

software
• Create dxf file • Create G code • Real time

control of the
machine
There are a lot of softwares for doing the tasks above. The CAD program is used for drawing the part
you want to cut. The CAM program is used for creating the G-code which the CNC control software
uses to control the machine.
Example of programs:
CAD programs:
- Autodesk Fusion 360

- Creo
- Onshape (free for personal use)
- Solid Edge 2D (free)
- Libre CAD (free)
- QCAD (free)
CAM programs:
- Sheetcam (most popular)

- Autodesk Fusion 360
CNC control software:
- Mach 3 (only work with parallel port breakout boards)

- Mach 4
- Linux CNC (only work with parallel port breakout boards)
- Planet CNC
- Command CNC (used on CandCNC kits)
My personal combinaton: Creo and Onshape – Sheetcam – Mach 3
Below are some important concepts of CNC plasma cutting:
Cutting direction: The best cut is to the right of the plasma arc, looking in the cutting direction. This
means that the outside edge of a part should be cut in clockwise direction and the inside edge(holes
etc.) should be cut in anti-clockwise direction. This can be set in the CAM program.
Cutting speed: Follow the recommended speeds of the plasma cutter. It may be necessary to slow
down a little because the recommended speeds tend to be a bit too high for a good cut quality. Holes
should be cut with slower speeds, 60 % of the recommended speed is a general rule to reduce taper
on the edge. It may be necessary to experiment with the hole cutting speed on different material
thickness and hole diameters. The THC should not be active during hole cutting. This can be
68
controlled from the CAM program if the CNC electronics and software allow for THC
activation/deactivation from the g code.
Acceleration settings: A high acceleration is desirable when cutting thinner plates. With a high
acceleration the speed can be maintained in the corners to a greater degree. If the step motors have
enough torque the acceleration settings could be set to 1000 mm/s² (0,1g) in the CNC control
software. I would not recommend setting a higher acceleration on this table even if the step motors
can handle it. It will increase wear and due to the rigidity the accuracy may be affected by induced
deformation and vibration.
Corner acceleration settings: When cutting around a corner edge there have to a trade off between
maintaining the speed of the cutting arc(correct speed is required for high cut quality) and the ability
to not get rounded edges due to change of direction. In the CNC control software, settings can be set
for the behavior at corners. In most cases a sharp edge is more important than the cut quality around
the edge. To get this result the arc have to decelerate to almost zero before the edge and after that
accelerate again. If the corner shapes is not important, the settings could be set to round the edges
instead of accelerating/decelerating. In Mach3 this setting is called CV mode. CV turned on means
constant velocity which leads to rounding of sharp corners. CV turned off means that the arc
decelerates in corners giving a correct edge of the detail.
Adjusting THC for different materials: Make some straight test cuts of 50-100 mm without the THC
activated. The cut height should be fixed at the recommended height according to the Plasma cutter
manual. Adjust the speed to get a good cut quality with minimal dross. When the speed is dialed in,
take note of the THC voltage during the cuts with good quality. Make a chart with different THC
voltages for different materials and thicknesses.
Adjusting kerf width: After the speeds and THC voltage are dialed in, the kerf width should be
adjusted. This is the width of the arc cutting in the material. This changes with speeds, material type
and thickness. Make a few test holes and measure the diameter on the top of the plate(the bottom
diameter maybe smaller due to taper). Adjust the kerf width in the CAM program until the holes get
the correct diameter. This should be done for every material and thickness you intend to cut. The
kerf width can also be adjusted by measuring the outer dimensions of a part, where the speed is
higher. Make a chart with different kerf widths for different materials and thicknesses.
Consumables: Make sure to inspect and change the consumables(electrode, nozzle and cap) of the
plasma torch regularly. Before troubleshooting the cut quality you should always make sure that the
consumables are in good condition.
Air: Use as dry air as possible for the plasma cutter. It is often enough to regularly drain the
compressor for water. A water filter can also be installed after the compressor. Some CNC plasma
machines use a dryer for the air before it reaches the plasma cutter. Make sure that the compressor
don’t have an air tool oiler installed.
69
Beams and Plates
No Part Name Description Where to buy Tot. Qty Total approx. cost
https://www.metals4u.co.uk
https://www.metalsdepot.com 300 $ for all beams, see drawings
1 BEAM_BOTTOM_Y Bottom Beam Y 50x50x3 or local hardware store 2 for lengths
2 BEAM_BOTTOM_X Bottom Beam X 50x50x3 - "" - 2 - "" -
3 BEAM_CORNER Vertical Corner Beam 50x50x3 - "" - 4 - "" -
4 BEAM_TOP_Y Top Beam Y 50x50x3 - "" - 2 - "" -
5 BEAM_TOP_X Top Beam X 50x50x3 - "" - 2 - "" -
6 BEAM_TRIANGULATION_X Triangulation Beam X 30x30x2 - "" - 2 - "" -
7 BEAM_TRIANGULATION_Y Triangulation Beam Y 30x30x2 - "" - 6 - "" -
8 BEAM_TOP_MIDDLE_Y Top Middle Beam Y 50x50x3 - "" - 1 - "" -
9 BEAM_VERTICAL_MIDDLE Middle Vertical Beam 50x50x3 - "" - 4 - "" -
10 BEAM_L_SUPPORT_40X40X3 L Profile Support 40x40x3 - "" - 96 - "" -
11 BEAM_RAIL_SUPPORT Beam for Rail Support 50x50x3 - "" - 2 - "" -
12 BEAM_RAIL_20X3 Rail Beam 20x3 - "" - 4 - "" -
13 BELT_FASTENER_Y Bracket for Y Belt - "" - 2 - "" -
14 BEAM_BELT_TENSION_Y_LEFT Bracket for Left Belt Tension - "" - 1 - "" -
15 BEAM_BELT_TENSION_Y_RIGHT Bracket for right belt tension - "" - 1 - "" -
16 BEAM_CHAIN_SUPPORT_Y Chain Support Beam Y - "" - 1 - "" -
17 MATERIAL_SUPPORT_50X3 Material Support Beam 50x3, 1750 mm - "" - 32 - "" -
https://8020.net/
18 BEAM_ALU_8080 Aluminium Beam 80x80, 1878 mm https://www.alucon.se 1 100 $
https://www.metalsdepot.com 300 $ for all waterjet/laser
19 BEAM_CHAIN_SUPPORT_X L Profile 20x2, supporting Cable Chain X or local hardware store 1 cutting
https://www.metalsdepot.com
20 BEAM_CHAIN_BRACKET L profile 20x2, Cable Chain attachment or local hardware store 2 - "" -
or supplied by waterjet/laser cutter company. Some of the plates also needs 300 $ for all waterjet/laser
30 SIDEPLATE_LEFT Sideplate Left machining. 1 cutting. 500 $ for all machining.
31 SIDEPLATE_RIGHT Sideplate right - "" - 1 - "" -
32 SIDEPLATE_INNER Sideplate Inner - "" - 2 - "" -
33 X_AXIS_PLATE_HORIZONTAL Horizontal Plate for X-Axis Wagon - "" - 1 - "" -
34 X_AXIS_PLATE_VERTICAL Vertical Plate for X-Axis Wagon - "" - 1 - "" -
35 X_AXIS_PLATE_LOWER Plate below X-Axis Driveshaft - "" - 1 - "" -
36 TENSION_BLOCK Block for Step Motor Tensioner - "" - 3 - "" -
37 CABLE_CHAIN_HOLDER_X Cable Chain Holder for X wagon - "" - 1 - "" -
38 BELT_FASTENER_X Fastener for X Belt and Chain - "" - 1 - "" -
39 TORCHPLATE Torch Breakaway Plate - "" - 1 - "" -
40 TORCH_HOLDER_BOTTOM Torch Holder Bottom - "" - 1 - "" -
41 TORCH_HOLDER_TOP Torch Holder Top - "" - 1 - "" -
42 TORCH_BREAKAWAY_MOUNT Torch Breakaway Mount - "" - 1 - "" -
43 BELT_TENSION_PLATE AT5 Belt Tensioner Plate - "" - 3 - "" -
44 TENSION_PLATE Plate for Motor Tensioner - "" - 3 - "" -
45 BELT_PROTECTION Plate for Belt Protection - "" - 2 - "" -
70
Beams and Plates
46 PLATE_STAND_1 Plate for Computer Stand or local hardware store 1 May be cut with cnc plasma
47 PLATE_STAND_LEFT Plate for Computer Stand - "" - 1 - "" -
48 PLATE_STAND_MIDDLE Plate for Computer Stand - "" - 1 - "" -
49 PLATE_STAND_RIGHT Plate for Computer Stand - "" - 1 - "" -
50 PLATE_STAND_BOTTOM Plate for Computer Stand - "" - 1 - "" -
51 PLATE_STAND_TOP Plate for Computer Stand - "" - 1 - "" -
52 PLATE_STAND_TOP_SUPPORT Plate for Computer Stand - "" - 1 - "" -
71
CNC Mechanics
60 DRIVESHAFT Driveshaft for Belts Machined out of steel 3 500 $ for all machining
61 DISTANCE_40MM Distance 40 mm - "" - 3 - "" -
62 DISTANCE_42POINT5MM Distance 42,5 mm - "" - 2 - "" -
65 DISTANCE_3_POINT_8_MM Distance 3.8 mm - "" - 6 - "" -
https://www.ebay.com/itm/10mm-Dia-Drill-Depth-Stop-Solid-Collar-Ring-for-
Dowels-Cavity-
Drilling/361352173272?epid=1338452981&hash=item54224496d8:g:FMgAAOSw
SdZaTT3r
66 STOP_RING Stop Ring for Driveshaft https://www.kullager.se/product.html/stoppring-sr-10---din705?category_id=96 3 10 $

https://www.ebay.com/itm/1-Stk-NTN-Rillenkugellager-Miniatur-Kugellager-628-
LLB-2RU-VV-8x24x8-mm/372199814245?hash=item56a8d67465:g:AKcAAOSw-
KFXeUSn
67 BEARING_8X24X8 Sealed Bearing 8x24x8 mm https://www.kullager.se/ 18 90 $
https://www.ebay.com/itm/6000-LU-NTN-Ball-Bearing-10x26x8-mm-deep-groove-
ball-bearing/222434093968?hash=item33ca1aeb90:g:miAAAOSw6btXRvGb
68 BEARING_10X26X8 Sealed Bearing 10x26x8 mm https://www.kullager.se 6 30 $

https://buildyourcnc.com/Item/bearing-v-groove-!375
https://www.ebay.com/itm/NEW-ONE-PCS-RM2ZZ-W2-W2ZZ-NW2-3-8-9-525-30-
73-11-1mm-V-Groove-CNC-
69 V GROVE BEARING V Groove Bearing 3/8" Bearing/302357785443?hash=item4665edab63:g:QTsAAOSwrfVZS15p 6 60 $
70 HTD3M_16T HTD3M Pulley 16 Teeth, for 9 mm Belt http://www.beltingonline.com/16-tooth-htd3-pulley-16-3m-09f-7718 3 15 $
HTD3M Pulley 48 Teeth 14 mm bore, for 9 mm
71 HTD3M_48T Belt http://www.beltingonline.com/48-tooth-htd3-pulley-48-3m-7731 3 15 $
http://www.beltingonline.com/3mm-htd-timing-belts-4573
https://www.ebay.com/itm/Zahnriemen-geschlossen-HTD-3M-Breite-9mm-Lange-
250mm-bis-
72 HTD3M_BELT_90T HTD 270-3M Belt, 90 Teeth 9mm 399mm/283051097523?hash=item41e728fdb3:m:mBG9uew03d9yT56l9FbHvBw 1 5$
http://www.beltingonline.com/3mm-htd-timing-belts-4573
https://www.ebay.com/itm/Zahnriemen-geschlossen-HTD-3M-Breite-9mm-Lange-
250mm-bis-
73 HTD3M_BELT_110T HTD 330-3M Belt, 110 Teeth 9 mm 399mm/283051097523?hash=item41e728fdb3:m:mBG9uew03d9yT56l9FbHvBw 2 10 $
AT5 Pulley 15 Teeth 10 mm bore, for 25 mm
74 PULLEY_AT5_15T Belt http://www.beltingonline.com/15-tooth-at5-pulley-al36at5-5078 3
72
CNC Mechanics
http://www.beltingonline.com/at5-e-brecoflex-timing-belts-1259
Use high quality belts for linear positioning from brands like Brecoflex, Optibelt
75 BELT_AT5 AT5 Belt etc. 8800 mm 200 $
76 BELT_CLAMP_AT5 AT5 Belt Clamp http://www.beltingonline.com/at5-clamp-plate-to-suit-25mm-width-belt-10330

6 30 $
https://www.jbcnc.se/en/cnc-mechanics-c-42/linear-bearings-c-44/supported-rail-
c-55/supported-rail-16mm-per-100mm-p-358
https://www.ebay.com/itm/2X-TBR16-2000mm-16MM-SUPPORTED-LINEAR-RAIL-
4-TBR16UU-Rounter-
77 SUPPORTED_AXLE_TBR16 Supported Axle TBR16 Bearing/141220009484?hash=item20e15e560c:g:bI8AAMXQCgpRxq9B 2 200 $ for rails and linear bearings
https://www.jbcnc.se/en/cnc-mechanics-c-42/linear-bearings-c-44/supported-rail-
c-55/open-pillowblock-16mm-p-360
https://www.ebay.com/itm/2X-TBR16-2000mm-16MM-SUPPORTED-LINEAR-RAIL-
4-TBR16UU-Rounter-
78 LINEAR_BEARING_TBR16 TBR16UU Linear Bearing Bearing/141220009484?hash=item20e15e560c:g:bI8AAMXQCgpRxq9B 4 - "" -
79 BELT_TENSIONER AT5 Belt Tensioner Assembly of other parts 3-
80 MOTOR_TENSIONER Step Motor Tensioner Assembly of other parts 3-
https://www.ebay.com/itm/Z-AXIS-ACTUATOR-X-CARVE-ONLY-4-75-TRAVEL-CNC-
ROUTER-3D-PRINTER/122720104895?hash=item1c92b031bf:g:iigAAOSwxLVZzA7L
https://www.ebay.com/itm/Ball-Screw-Linear-CNC-Slide-Stroke-60mm-400mm-
Long-Stage-Actuator-Stepper-
81 Z_AXIS Z-axis Assembly Motor/292138883593?hash=item4404d59a09:m:m88C6-uYA-NNwR2sSb-_laQ 1 50-200 $
73
Electronics
90 POWERMAX_45 Plasma Cutter local dealer, amazon etc. 1 1000-2000 $
91 TORCH_T45M Machine Torch - "" - 1 200-500 $
https://www.candcnc.net/
https://www.cncrouterparts.com
https://www.flashcutcnc.com 2500 $ (cheaper if building DIY
92 CNC_ELECTRONICS CNC Control Electronics https://www.procutcnc.com/ 1 electronics)
100-300 $ (or included in kit
93 STEPMOTOR_NEMA23 Nema 23 Step Motor - "" - 4 above)
https://www.ebay.com/itm/1Pc-V-153-1C25-Long-Straight-Hinge-Lever-Type-
SPDT-Micro-Switch-Limit-
94 LIMIT SWITCH BESAR Limit Switch NO/NC, Long Arm Switch/292702015903?hash=item442666519f:g:eG8AAOSwcyVbhjfw 7 1$
https://www.ebay.com/itm/1pcs-x-22mm-1-NO-N-O-Green-Sign-Momentary-
Push-Button-Switch-600V-10A-ZB2-
EA31/132292798059?hash=item1ecd43e66b:g:61YAAOSw7RdZwzF4
https://www.ebay.com/itm/Momentary-Push-Button-Switch-22mm-Flush-Mount-
SPST-ON-OFF-
C8A2/122386872947?epid=1368953945&hash=item1c7ed37a73:g:TccAAOSwSlBY
95 PUSH_SWITCH Push Switch, Momentary On vwP5 1 5$
https://www.buildyourcnc.com/item/electronicsAndMotors-electronic-
component-e-stop-button-switch-safety
https://www.ebay.com/itm/Red-Mushroom-Cap-1NO-1NC-DPST-Emergency-Stop-
Push-Button-Switch-AC-660V-
96 EMERGENCY_STOP Emergency Stop Switch NO/NC 10A/162122517814?hash=item25bf414d36:g:JusAAOSwT0NbVmHT 1 10 $
https://www.ebay.com/itm/Diode-Laser-Rouge-en-ligne-3V-20mA-avec-cables-
Niveau-Arduino-Raspberry-
DIY/222622837386?hash=item33d55aea8a:g:olwAAOSw3ONZntWO
https://www.ebay.com/itm/Industrial-linear-Red-Line-3-5V-650nm-5mW-
Focusable-Adjustable-Laser-Head-
97 LINEAR_LASER Linear Laser, 3 Volts ATF/192417186043?hash=item2cccf540fb:g:Y50AAOSwEZdZ8hzT 2 10 $
https://www.ebay.com/itm/Braided-Earth-Strap-30A-Grounding-Flexible-Wire-
Ground Connecting Cable 250 mm, Cable Lugs 100-400mm-M4-M10-
98 GROUND_CONNECTOR with 8 mm hole 000877/263544743941?hash=item3d5c7da805:m:mxxFuHDE_g0oe9UB5SUqqqQ 1 5$
Cables for Plasma/Electronics. Straps,
99 CABLES Connectors, Shrink Tubing etc. ebay, amazon etc. 1 30 $
100 COMPUTER Computer - "" - 1 200 $
101 BENQ 21.5'' LED MONITOR Computer Monitor - "" - 1 100 $
102 KEYBOARD Keyboard - "" - 1 10 $
103 MOUSE Mouse - "" - 1 10 $
74
Nuts, Bolts and misc.
https://www.screwfix.com/
https://www.homedepot.com/
50 $ for all nuts, bolts, washers
110 ISO4017-M3X16-8_8 M3x16 Bolt, Hexagon Head or local hardware store 1 etc.
111 ISO4762-M5X10-8_8 M5x10 Bolt, Allen Head - "" - 42 - "" -
113 ISO10642-M5X16-8_8 M5x16 Bolt Countersunk - "" - 4 - "" -
117 ISO4032-M5-6 M5 Nut - "" - 42 - "" -
118 ISO4017-M6X12-8_8 M6x12 Bolt, Hexagon Head - "" - 72 - "" -
126 ISO4032-M6-6 M6 Nut - "" - 16 - "" -
130 M8X110_BOLT M8x110 Bolt, Hexagon Head - "" - 3 - "" -
131 ISO4032-M8-6 M8 Nut - "" - 18 - "" -
132 WASHER_M8_1POINT6MM M8 Washer, 1.6 mm Thickness - "" - 12 - "" -
133 HEXSOCKSCREW-3_8-16X1_5 3/8"-16x1.5" Bolt - "" - 7 - "" -
134 HEXNUT-3_8-16 3/8"-16 Nut - "" - 7 - "" -
135 M10X110_BOLT M10x110 Bolt - "" - 2 - "" -
136 THREADED_ROD_M10X180 M10x180 Threaded Rod - "" - 2 - "" -
137 ISO4032-M10-6 M10 Nut - "" - 10 - "" -
138 M10_WASHER_2MM M10 Washer, 2 mm Thickness - "" - 4 - "" -
139 DRILLING_SCREW_4_8X13 Self Drilling Screw 4,8x13 - "" - 6 - "" -
140 SPRING_PIN_3X18 Spring Pin 3x18, for 3 mm hole - "" - 3 - "" -
https://8020.net/
141 T_SLOT_NUT_M8 M8 T-slot Nut, size 8 https://www.alucon.se 2 2$
https://www.ebay.com/itm/4-Red-Wheel-Casters-Set-5-Wheels-All-Swivel-Heavy-
Duty-Iron-Hub-No-Mark-2-
Brake/282891105366?epid=1383843715&hash=item41dd9fb456:g:eT0AAOSwnM
1baZ1g
151 CASTER_WHEEL_PIVOT Pivoting Caster Wheel or local hardware store 4 50 $
75
Nuts, Bolts and misc.
https://www.buildyourcnc.com/item/cable-carrier-2x!75-cablecarrier
https://www.jbcnc.se/en/cnc-accesories-c-5/cable-carrier-23x50mm-p-511
https://www.ebay.com/itm/1M-40-R38-18mm-x-37mm-CNC-Machine-Towline-
Nylon-Cable-Drag-Chain-Wire-
Carrier/192363996731?epid=16009501680&hash=item2cc9c9a63b:g:B5MAAOSw
152 CHAIN_LINK Cable Chain Link JtdaCaLc 5800 mm 40 $
153 CHAIN_END_1 Cable Chain End, type 1 often included in chain kit 2-
154 CHAIN_END_2 Cable Chain End, type 2 often included in chain kit 2-
https://www.ebay.com/itm/10Pcs-20x5mm-Super-Strong-Round-Disc-Magnets-
Rare-Earth-Neodymium-
Magnet/382568311279?hash=item5912d929ef:g:RykAAOSwhjxboiZF
http://www.magnetvaruhuset.se/product.html/ring-
155 MAGNET_20X5 Torch Breakaway Magnet 20x5 neodymmagnet?category_id=22 4 5$
Total cost: 4000-7000 $ depending on Electronics, Plasma Cutter and how much of the machining is outsourced or not.
76

CNC Plasma 5x10

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100 x31 100 x31

WHEN PAINTING THE FRAME, MAKE SURE THAT "GROUND_CONNECTOR"[98]

MIDDLE L-SUPPORTS IN THE OPPOSITE

No Part Name Description Qty

NO MTRL. SECTION TOT. QTY.

NO MTRL. SECTION TOT. QTY.

NO MTRL. SECTION TOT. QTY.

NO MTRL. SECTION TOT. QTY. NO MTRL. SECTION TOT. QTY.

NO MTRL. SECTION TOT. QTY. NO MTRL. SECTION TOT. QTY.

ASSEMBLYS OF LEFT AND RIGHT

No Part Name Description Qty

NO MTRL. SECTION TOT. QTY.

NO MTRL. SECTION TOT. QTY.

NO MTRL. SECTION TOT. QTY.

FOR RIGHT RAIL

NO MTRL. SECTION TOT. QTY.

80 DXF FILES FOR CUTTING INCLUDED

NO MTRL. THICKNESS TOT. QTY.

MAKE SURE THAT THE RAILS ARE LEVELLED,

No Part Name Description Qty

124 133 126 30

140 74 63 132 132 67 61 65 32 68 129

ASSEMBLY OF RIGHT SIDE WAGON IS MIRRORED TO LEFT SIDE WAGON.

No Part Name Description Qty

RIGHT SIDE WAGON IS MIRRORED TO THE LEFT SIDE WAGON,

NO MTRL. THICKNESS TOT. QTY.

NO MTRL. TOT. QTY.

DXF FILES FOR CUTTING INCLUDED, BEARING SEAT NEEDS MACHINING

NO MTRL. THICKNESS TOT. QTY.

NO MTRL. THICKNESS TOT. QTY.

DXF FILES FOR CUTTING INCLUDED

No Part Name Description Qty

NO MTRL. TOT. QTY.

NO MTRL. TOT. QTY.

NO MTRL. TOT. QTY.

NO MTRL. TOT. QTY.

2 CLAMPING SCREWS AT MINIMUM

65 140 35 74 66 68 129 114

No Part Name Description Qty

DXF FILES FOR CUTTING INCLUDED,

NO MTRL. THICKNESS TOT. QTY.

MAKE ADDITIONAL HOLES FOR ATTACHING THE Z-AXIS

6 NO MTRL. THICKNESS TOT. QTY. 6

121 40 97 122 126 39 119

No Part Name Description Qty

NO MTRL. THICKNESS TOT. QTY.

NO MTRL. THICKNESS TOT. QTY.

DXF FILES FOR CUTTING INCLUDED

NO MTRL. THICKNESS TOT. QTY.

DETAIL A SCALE 2:1

No Part Name Description Qty

DXF FILES FOR CUTTING INCLUDED

NO MTRL. THICKNESS TOT. QTY.

Steps for troubleshooting of belt climbing:

1. Use proper tension as described above

MAKE SURE THAT THE SIDEWAGON IS PERPENDICULAR TO 117

77 111 114 18 114

No Part Name Description Qty

INSTEAD OF USING THREADED HOLES AND BOLTS, RAILS AND

SECTION A-A SCALE 1:2

6.5 SECTION B-BSCALE 1:2

M5 x13 BEAM ENDS, 20 MM DEEP 49