2D Plasma Design Programs/Software?

[EWheeler]

I am proficient in AutoCAD LT for 2D drafting & structural design. Currently use the program to do shop drawings for a small fabrication shop and create profiles as necessary to cut on our 5x10 plasma table for our structural work. We do not get into ornamental stuff at all in our day to day operations and I can count on one hand the number of times that I have cut out anything with text on it. I have been asked to take our company logo and make it into a small plaque....easier said than done when considering kerf width and letter size..... I've wasted nearly a days time trying to edit a dxf file of our logo into something that I am physically able cut on our table, and am not getting anywhere. I started researching plasma sign / text design software and found a few options. I am curious if any of you have experience with this type of work, and what programs/software you use?

The biggest hurdle I am running into is the letters are just too small for the minimum kerf width of our machine (50amp minimum setting for thin material has a kerf width of approximately 0.060"). Are there programs that take this into account when designing text for plasma cutting, or is it always up to the user to keep machine limitations in mind while designing? I ran into a similar issue a couple years ago when I cut out a sign for a friend of a friend. It turned into an 8hr endeavor that I didn't get paid for....

I know there has to be a program out there that has hundreds of fonts and maybe even a repository of dxf files to purchase for use. Every time I have taken an image and converted to dxf, it takes me hours of editing the tiny lines to make it into something that is cut able on our table....

A couple examples, both of which took an embarrassing amount of hours to make them look right with my caveman technology and methods:

What I am trying to turn into something that is cut able on the plasma. I can make it work if it's a 24 x 36 size, but looking to get this down to like 4x6 for posting on equipment and fabrications we put out for private customers.

I have got it cleaned up to this point, but the letters are still just far too tight. Maybe its not possible, or I need to use a laser or water jet..... definitely going to cut the star out individually and tack it on top of the cut out placcard.

 

[PAToyota]

Kerf width - or tool width - is a constant problem. I do plasma cutting and also have access to a CNC mill and lathe. People constantly approach me wondering if I can cut or machine something they have an image of or have "drawn up in CAD" that is near impossible to actually process. Kerf/Tool width is the most common problem and I haven't found any software that processes it automatically.

Basically, I'll start with something like the designs you posted and go through it and offset lines to make things wider until it can be done - like the "certified" in your image - and add "bridges" to keep things whole - like the centers for the "D" and "A" in your image. Of course, if you're cutting out the letters and then applying them to a backer instead of just cutting them out of a single sheet, the bridges aren't necessary.

As you say, using a laser or waterjet does get you a bit more precision, but I still get people who want something small and delicate cut out of 16ga or thicker and expect it to be print quality. You just have to explain to people that there are limitations.

I use a few different CAD programs - Vectorworks, Fusion360, or LibreCAD - depending on what I'm doing. Even for the 2D stuff, it is nice to be able to work in 3D and show them a rendering of it or add other details. If I'm starting with an image file, I use the Affinity software (Creative Freedom Is Coming - Affinity - https://affinity.serif.com/en-us/) to turn it into an svg, eps, or dxf file and may do some work on it as an image first before turning it into a vector.

 

[EWheeler]

Basically, I'll start with something like the designs you posted and go through it and offset lines to make things wider until it can be done - like the "certified" in your image - and add "bridges" to keep things whole - like the centers for the "D" and "A" in your image. Of course, if you're cutting out the letters and then applying them to a backer instead of just cutting them out of a single sheet, the bridges aren't necessary.

Thanks for your input. Your explanation quoted above, is EXACTLY my process. Painstakingly joining the tiny little lines that are created by the DXF convert program to bring an image into CAD or even worse, making hundreds of new lines because the convert program created a bunch of arcs/splines that wont join to straight 2pt line segments in AutoCAD…..all to create one continuous single line segment for the outline and then start the offset game to scale things to a point where it looks proper at 1:1 and is physically able to be cut. Then go in and physically add the bridges to keep the internal parts attached to the plate. Its a PITA and there has got to be a better way.

I will check out Afinity. I convert images to DXF so rarely that i dont pay for a software, just use a free site from the web.

 

[PAToyota]

Yeah, I've tried a couple of the free sites and they really create a bazillion line segments. Something like Affinity or Adobe Illustrator does a much better job with fewer line segments and more control. I have the full suite, but I'd at least get Photo and Designer to be able to edit both raster and vector - there are advantages to each in the workflow to cutting/machining.

I moved to Affinity rather than pay Adobe monthly rent on their software. There is a large community with tutorials, videos, plugins, and such. They also have a generous trial period. They did get bought out by Canva awhile back, but so far there hasn't been much of a change or negative effects from that.

If you try it and like it, in past years there have been generous discounts around Black Friday / Cyber Monday. Even at full price, it is less than the cost of a year of Adobe rental.

 

[EWheeler]

Yeah, I've tried a couple of the free sites and they really create a bazillion line segments. Something like Affinity or Adobe Illustrator does a much better job with fewer line segments and more control. I have the full suite, but I'd at least get Photo and Designer to be able to edit both raster and vector - there are advantages to each in the workflow to cutting/machining.

I moved to Affinity rather than pay Adobe monthly rent on their software. There is a large community with tutorials, videos, plugins, and such. They also have a generous trial period. They did get bought out by Canva awhile back, but so far there hasn't been much of a change or negative effects from that.

If you try it and like it, in past years there have been generous discounts around Black Friday / Cyber Monday. Even at full price, it is less than the cost of a year of Adobe rental.

I ditched Adobe Acrobat due to the subscription and annoyance of their approach to business. Changed to PDF XChange Editor by Tracker Software and haven't missed Acrobat once.

 

[PIP]

I use Mastercam, so not much help on the software.

When I'm making text and logos for laser cutting or machining I do tweak the designs a lot. I'll import an artsy DXF and then spend many hours converting all the little segments into smooth arcs and simpler geometry so machines can wiz through it.

You might look into laser instead of plasma. Sendcutsend is a good company to deal with.

 

[PAToyota]

Just to follow up on this, I had mentioned that Canva had bought Affinity. Well, they've now made it free: Unsupported client - https://www.affinity.studio/get-affinity

I'm actually surprised by this. They had always had a fair price as far as I was concerned and often had generous discounts (Black Friday, etc). I need to find some time to read up on this change. I won't complain that they made it free, but I wonder either 1) how they intend to profit now and 2) what it portends for the future of Affinity? If there is no profit are they going to phase it out? Is there something I'm not seeing (yet) that is going to be the profit driver?

They have a free version of Canva (which now seems to give you access to Affinity), but then you can subscribe for more features - including AI integration. Affinity is pretty powerful and I just hope they don't dumb it down.

 

[ntsqd]

For really fine stuff my first thought is wire EDM. It's kerf is the wire OD + some small factor (.002"?). There's actually a book out there on how to build one for home shop / modest use.

 

[PIP]

For really fine stuff my first thought is wire EDM. It's kerf is the wire OD + some small factor (.002"?). There's actually a book out there on how to build one for home shop / modest use.

It would be an unusual case to use WEDM to cut a sheetmetal sign. WEDM is the most expensive process.

If you had a sign with tiny features cut all the way through sheetmetal you could do it with fiber laser more effectively than WEDM.

WEDM could make sense in the rare case you have hundreds of thin parts with tiny, accurate features to make. You stack all the sheets and clamp between thicker sacrificial plates and cut all of them at once.

WEDM is a very niche process. My neighbor owns the largest WEDM shop in the NW US. Very fascinating work.

 

[ntsqd]

Don't really care if it's an unusual process for the use or not. The OP isn't looking for a million of them. Small kerf demand is easily met by it; plasma, laser, and waterjet can't compete on that aspect. True, it isn't inexpensive and it isn't fast (although in a thin stack of sheet metal..... ), which is why I mentioned the book on building your own machine. Aside from the wire feed aspect it can't be much more complex than building an 80/20 based plasma table.

 

[PIP]

Aside from the wire feed aspect it can't be much more complex than building an 80/20 based plasma table.

We live in different worlds man.

I cannot fathom a bigger waste of time than a DIY WEDM.

 

[ntsqd]

It's not something that I have a need for, so I'm unlikely to build one just because. But for a specific need that can't easily be met by some other, lower cost/involvement method I wouldn't hesitate. In R&D the most direct path to the goal is usually the correct choice, even if you're using a tool or process outside of it's typical application(s). Which shouldn't be taken to mean that tools and processes should be abused, just used in unusual ways.

 

[EWheeler]

Don't really care if it's an unusual process for the use or not. The OP isn't looking for a million of them. Small kerf demand is easily met by it; plasma, laser, and waterjet can't compete on that aspect. True, it isn't inexpensive and it isn't fast (although in a thin stack of sheet metal..... ), which is why I mentioned the book on building your own machine. Aside from the wire feed aspect it can't be much more complex than building an 80/20 based plasma table.

Yeah, I'd just not do the work versus going down this rabbit hole of making a $100 part cost thousands of dollars not accounting for the time wasted. Do you work for NASA?

 

[ntsqd]

Nope, but I am employed in solving one-off and weird problems. It was stated that the kerf width was an issue so I posted a possible solution with a possible means to make it less costly. My bet was that in light of the cost that the kerf width would suddenly be much less of a problem.