Contents

Chapter 7

Tutorial

7-1

Starting the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Adjusting the Program Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Using Undo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Basic Drawing and Zooming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
More Zooming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Selecting Parts of the Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Advanced Drawing and Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Creating a Simple Dimensioned Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Creating a Complex Dimensioned Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
Nesting Parts and Preparing for Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
Importing and Converting a Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24
Importing and Converting a Picture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
Building a Computer Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Cutting the Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Bending the Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
Assembling the Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34
Finishing the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35

7
Tutorial

This chapter is designed to help you learn how to use the PlasmaCAM software in a way that is
fun and easy. You learn by working through actual examples. The chapter contains examples to
demonstrate every important feature of the software. You will probably want to work through
the examples more than once, as well as trying your own similar projects.
You should already possess basic computer skills before attempting to learn the software from
this manual. If you are not familiar with the general operation of a Windows-based personal
computer, please seek to learn. You can learn from a class or from a friend. Your local
bookstore can recommend any one of several excellent books available.
You should be versed with at least the following skills:
Able to operate both the keyboard and mouse in commonly used ways
Able to save and open files from the hard drive, and use file directories (folders).
Able to start and operate basic Windows programs.
Most of this chapter focuses on familiarizing you with the softwarenot so much on how to
operate the machine. CHAPTER 5 contains the most information on actually operating the
machine. It is good to experiment on your own, trying out different things in the software.
However, be careful not to do this with the machine because of obvious dangers.
Many of the softwares functions and capabilities are not covered in this chapter. As you become
familiar with the software, take time to read through CHAPTER 6. Practice with all of the
commands and settings described to fill in the gaps in what you have learned.

7-1

Starting the Program

Before you can begin, you must have the program installed on your computer. Refer to
CHAPTER 4 for installation instructions.
With your computer turned on and with Microsoft Windows running, click the Start button at
the lower left corner of the screen. From the Programs menu, choose PlasmaCAM >
PlasmaCAM.
After the program starts, make sure that the program window is maximizedthat it fills the
whole screen. If it is not, click the maximize button ( ) at the upper right corner of the
window.
Adjusting the Program Settings
You must have the program settings correctly set before doing any of the examples given in this
chapter. Otherwise, some of the commands may not generate the expected results.
From the VIEW menu, choose Settings. Make sure that everything is set according to what is
shown below in the Drawing View and Path Conversion tabs:

7-2

When you are done, click the OK button.

Using Undo
While you are working on the examples given in this chapter, you may accidentally do something
differently than what is given in the instructions. This may result in the drawing being changed
in a way that would require you to start the example over again. Rather than do this, use Undo
from the EDIT menu to take back instructions. Undo does not affect program settings or zoom
settings (see CHAPTER 6 for more on Undo).

7-3

Basic Drawing and Zooming

The picture shown at right represents the
computer screen. The outer rectangle is
simply the edge of the programs drawing
area. These pictures will show you where
to click with the mouse in order to draw
the example shapes.
From the DRAW menu, choose Rectangle.
Move the mouse to point 1 and left click
(quickly press and release the left mouse
button). Then move the mouse to point 2
and left click. As a result, a new rectangle
is drawn on screen, appearing in green.
From the VIEW menu, choose Zoom
Extents. This magnifies the drawing so
that it fills the screen.
From the DRAW menu, choose Circle.
Left click at point 1, then move to point 2
and left click.
From the DRAW menu, choose Line(s).
Left click at points 3 and 4. Then right
click to end the command.
Press the spacebar on the keyboard to
quickly repeat Line(s). Left click at points
1 through 3, in order. When you are
finished, right click to end the command.

From the DRAW menu, choose Text. Left

click at point 1 then 2. When the dialog
box appears, type in Test at Text.
Under Font, choose Arial from the list.
Then click OK at the bottom of the box.
From the DRAW menu, choose Arc. Left
click at points 3 through 5, in order.
Notice that the arc just drawn is green,
while the other shapes are different colors.
Green indicates that the path is selected.
7-4

Since the arc was just drawn, it is

automatically the only thing selected in the
drawing (otherwise select it).
From the VIEW menu, choose Zoom
Selection. This magnifies what is selected
within the drawing (the arc) so that it fills
the screen.
From the DRAW menu, choose Bulge.
Left click at points 1 through 3, in order.
From the VIEW menu, choose Zoom
Previous. This returns the magnification
to the previous viewpoint.
From the DRAW menu, choose Chamfer.
Left click at points 1 through 6, in order.
(Points 1 and 2 set the size of the chamfer;
click just inside the corners for the other
points so the program knows what corners
to chamfer.) Then right click to end the
command.
From the DRAW menu, choose Fillet.
Left click at points 1 through 5, in order.
(Points 1 and 2 set the radius of the fillet;
click just inside the corners for the other
points so the program knows what corners
to fillet.) Then right click to end the
command.

7-5

More Zooming
You have already seen how Zoom
commands on the VIEW menu can be used
to magnify part of the drawing or show
parts of the drawing that are hidden
because they are off the screen. Zoom
Extents, Zoom Selection, and Zoom
Previous were all demonstrated in the
previous examples. You will notice that
other Zoom commands can be found on
the VIEW menu.
Choose Zoom Window from the VIEW
menu, and left click at points 1 and 2.
The region of the drawing contained
within the window you drew is enlarged to
fill the screen. Because of its usefulness,
Zoom Window is the most commonly used
command in PlasmaCAM. Notice that
next to Zoom Window in the VIEW menu
is the keyboard shortcut F1. The F1 key is
conveniently located on your keyboard to
give you quick access to the command.
In addition to VIEW commands appearing
on the menu, you can also use the arrow
keys on the keyboard to pan around the
drawing. For example, press the up arrow
key.
The drawing view changes so that you can
see what was above the previous view.
Each press of an arrow key pans the
drawing by the screen width (or height).
Experiment by pressing the arrow keys to
pan around the drawing.
Press the F4 key on the keyboard when you are finished experimenting with the arrow keys, so
the drawing is centered back on screen. (F4 is the keyboard shortcut for Zoom Extents.)
You can also use the scroll bars to pan around the drawing. The scroll bars can be seen at the
bottom edge and the left edge of the drawing (bottom scroll bar is shown):
Arrow - click to pan 1/10th a screen

Slider - drag to pan

Click here to pan about a screen

Experiment with the scroll bars by clicking on the arrows at the ends of the bars. You will
notice that the field of view pans by about 1/10th of the screen. If you click just inside of the
7-6

arrows, you will notice that the field of view pans by a greater distance. The most convenient
way to use the scroll bars is to draw the slider (hold down the left mouse button over the slider
and move the mouse to drag). This allows you to manually pan the drawing by the amount you
desire.
Press the F4 key on the keyboard when
you are finished experimenting with the
scroll bars, so the drawing is centered back
on screen.
From the VIEW menu, choose Zoom Out.
This reduces the apparent size of the
drawing by a factor of two, allowing you
to see a larger area. (Zoom commands do
not move or change the actual size of the
drawing, they merely affect what parts of
the drawing you see on screen.)
From the VIEW menu, choose Zoom
Table. This frames the viewpoint so that
you can see the entire 5ft x 10ft cutting
area of the machine. The edge of the
square cutting area is designated on screen
by the gray box. Shapes that lie within
this area can be cut out by the machine.

7-7

Selecting Parts of the Drawing

In order to use many of the PlasmaCAM commands, you must first select something in the
drawing. For example, you can erase shapes by choosing Delete from the EDIT menu (or by
pressing the Delete key on the keyboard). However, something first has to be selected so the
program knows what to erase.
Press F4 on the keyboard (for Zoom
Extents). Then use the mouse to left click
on the circle in the drawing (point 1).
Notice that the circle turns green. Now
click on the letter T in the drawing
(point 2). Notice that the letter turns
green, while the circle returns to its normal
purple color. Green indicates that a shape
is selected. Notice that the status bar at
the bottom of the window reads 1 paths
are selected (9 nodes total). The letter
T is a path made up of nine points; the
status bar always tells you how many
paths are selected in the drawing.
A fast way to select several paths at once
is to use a selection window. For example
to select all the letters at once, hold down
the left mouse button at point 1. Then
drag the mouse cursor over to point 2 and
release the button. All of the letters turn
green, indicating that they are selected.
Notice that none of the large chamfered
rectangle is selected, even though part of it
was within the selection window. In order
for a path to be selected by a window, it
must lie entirely inside of the window.
Suppose you wanted to erase all of the
letters except the hole inside of the e, as
well as the rounded triangle and the inside
arc of the moon shape.
You can select and unselect multiple
shapes by holding down the Ctrl key as
you select. While holding Ctrl, drag a
selection window from point 1 to point 2.
Still holding Ctrl, left click at points 3 and
4. Because the hole of the e was already
selected, clicking on it while holding Ctrl
causes it to become unselected.
7-8

Press Delete to erase the selected shapes.

Notice that all of the intended paths are
now erased.

7-9

Advanced Drawing and Editing

From the FILE menu, choose New. Click
the No button to indicate you dont want
to save the drawing.
From the DRAW menu, choose Line. Type
24,24 and press the Enter key. (The text
you type will appear in the status bar at the
bottom of the screen.) Then type
<120,4 and Enter. Press Escape to end
Line. This draws a line from the center of
the cutting area to a point that is 4 inches
away at an angle of 120 degrees.
Since the new line is already selected, you dont have to select it to make a copy.
From the EDIT menu, choose Copy. Type @0,0 and Enter. Again type @0,0 and Enter.
Press the Esc key to end Copy. Although you cannot see it, you just made a second copy of the
line segment that lies exactly on top of the original. The coordinates you entered told the
program to copy the line from the last point picked to the last point picked, which is the upper
point of the line.
From the EDIT menu, choose Mirror.
Type @0,0 and Enter. Type @0,-1
and Enter. This changes the copy so that it
is a mirror image of the original. The
mirror line that was specified extended
from the upper end point of the line to a
point that was 1 inch directly below.
You can no longer see the original line
because it is not showing on the screen.
From the VIEW menu, choose Redraw
Screen. Now both lines can be seen.
Select both line pieces by dragging a
selection window around them. From the
DRAW menu, choose Array. At the top of
the dialog, check Polar. Enter 8 at
Number of rotated copies. Also check
Adjust rotation angle to fill 360 degrees.
Then press OK. Type @0,-5 and Enter.
Press F4 (for Zoom Extents).
Among other things, this exercise
demonstrates how you can type in
coordinates to specify exact points in the
drawing. The three types of coordinates used are absolute, relative and relative polar. Absolute
coordinates simply specify an X,Y point in the drawing. Relative coordinates (preceded by @
7-10

or <) specify how the new point is to be positioned relative to the last point picked. If you do
not have previous experience working with coordinates, see COORDINATE SYSTEM in
CHAPTER 6 for a detailed explanation.
From the DRAW menu, choose Fillet.
Type 0 and Enter. Then left click at
points 1-8. Click just inside of the corners
you want trimmed; then right click (or
press Esc) to stop Fillet. If you
accidentally click in the wrong place on
one of the points, stop Fillet and choose
Undo from the EDIT menu to take back
the mistake. Then restart Fillet.
Note that Fillet (or Chamfer) does not
actually add an arc segment if you type a
radius of 0. Instead, the line segments are simply trimmed at their intersection.
A couple of the line segments should still be selected from the last Fillet (otherwise select
something). From the EDIT menu, choose Link Segments. This joins all of the separate pieces
together to form one continuous, closed path. Unselect the shape (left click anywhere in the
drawing area); you will notice that the path is now purple, indicating that it is closed.
From the DRAW menu, choose Text. Left
click at points 1 and 2. From the Font list,
choose Playbill. (If this font is not
available, try Arial or any other font you
want to try.) Then type Hank at Text.
Click the OK button.

From the EDIT menu, choose Scale

Height. Click at points 1 and 2. Then
move the mouse to observe how you can
affect the height. Click at point 3 to make
the text a little shorter.
From the EDIT menu, choose Slant. Click
at points 1 and 2. Then move the mouse
to observe how you can skew and slant the
letters. Click at point 4 to make the text
lean a little to the left.

7-11

In the VIEW menu, check Snap to

NodePoints. You will notice the letter
N appearing near the center of the status
bar, indicated that this snap is activated.
From the DRAW menu, choose Line(s).
Left click near points 1 and 2. Right click
to end Line(s), then press the SpaceBar to
repeat it. Left click near points 3 and 4.
When you click near a line segment, Snap
to NodePoints automatically causes you to
pick exactly at the nearest endpoint of that
segment. Snaps allow you to draw very
accurately and quickly (see the SNAPS
section in CHAPTER 6).
Press F4 (for Zoom Extents).
Drag a selection window around all of the
lettersfrom point 1 to point 2.
From the EDIT menu, choose Move.
Click the middle mouse button (press
key or Shift+F10 on the keyboard if you
dont have a middle mouse button.) A
menu pops up from which you should
choose Midpoint Snap. You know that
you activated the snap if the center of the
status bar now shows also the letter M.
Left click at point 3. Type M (activate
Midpoint Snap again, without opening the
menu this time) and left click at point 4.
Now the text has been moved so that it is
centered with the star.
From the EDIT menu, choose Scale.
Again choose Midpoint Snap, either by
typing M or using the popup menu. Left
click at point 1, then at point 2. Move the
mouse to observe how you can change the
size of the text. Left click at point 3 to
make the text well sized for the star.
Select the two extra line segments, and from the EDIT menu, choose Delete (or just type the
Delete key).
To make the star 10 inches across, drag a selection window around everything. From the EDIT
menu, choose Scale. Left click at points 1 and 2. Then type 10 and Enter.
Press F4 (for Zoom Extents).
7-12

Unselect everything by clicking in the

drawing area. To prove that the star is
exactly 10 inches across, choose Measure
from the VIEW menu. Left click near
points 1 and 2. A message box indicates
the distance you measured to be 10.000
inches. The star has been sized exactly
because Snap to Endpoints was active
when you scaled it.
If you want to actually cut out this shape,
you need to fix the letter a. Currently
the letter has a hole inside of a hole.
From the VIEW menu, choose Zoom
Window. Left click at points 1 and 2.

From the DRAW menu, choose Line(s).

Left click at points 1 and 2. Right click to
end Line(s), then press the SpaceBar to
repeat it. Left click at points 3 and 4.
Because of NodePoint Snap, these new
lines should connect exactly to the
existing parts of the a as shown. The
lines should not overlap any parts of the
a, otherwise the next step will not work.
From the EDIT menu, choose Trim. Left
click at points 1 and 2 (until the a is
cleaned up as shown). Then right click to
end Trim.
Notice that Trim caused the a to be
broken up into pieces, so that it is no
longer one continuous closed path. In
order for this letter to be cut out properly,
it needs to be converted into a closed
(purple) path again. A couple of segments
of the letter should still be selected, so
from the EDIT menu, choose Link Segments. If you unselect the letter, it should now be purple.
(If it is not, choose Undo for Link Segments and closely inspect the trimmed corners to verify that
no gaps or overlapping segments are present. Fix the letter and try Link Segments again.)
Press F4 (for Zoom Extents).
7-13

From the MACHINE menu, choose

Convert to Cut Path. Left click on point 1
(just outside of the perimeter), then right
click to end the command. If you unselect
everything, you will notice that all the
paths have changed to blue. This means
that they are cut paths that can be followed
by the machine to actually cut the shape.
Not only have the paths changed color, but
they have also been offset from the
original shape to compensate for the kerf
width of the torch.
Furthermore, each path has a pierce start point that is off of the path, and a gap at the end of the
path. If you repeatedly choose Undo and Redo (EDIT menu, or just press Page Up and Page
Down keys), you can watch the shape as it changes from the original shape to the machine
cutable shape.
It is too early to actually cut out the shape, but you can simulate cutting of the shape. Make sure
that you Redo all of the Undos, so that you have all machine paths again. All of the paths should
be selected. From the MACHINE menu choose Cut Preview. Set Preview Cut Speed to 1000,
and check Time delay between cuts. Enter 1 at Time delay, and press the OK button. Cut
Preview demonstrates on screen how the shape will be cut out.

7-14

Creating a Simple Dimensioned Part

Suppose you wanted to make the part
shown at right. Rather than just drawing
the part by eyesight, you want it to be the
exact same shape and size as what is
shown.

From the FILE menu, choose New (you do

not need to save the other file).
From the VIEW menu, choose Settings.
Check Show grid and Snap to grid.
Enter 1 at Grid point spacing and 4
at Snap points per grid point. Make sure
Snap to node points and Snap
orthogonal are not checked.
From the VIEW menu, choose Zoom
Window. Left click at points 1 and 2.
From the DRAW menu, choose Line(s).
Left click at points 1 through 5. Then
right click to end the command.
Be sure to click in the right areas between
the grid points so that the lines snap to the
points that make them the right size,
exactly as shown.

From the DRAW menu, choose Bulge.

Left click at points 1 and 2. Next type in
2 and Enter. Then left click at point 3.
From the EDIT menu, choose Link
Segments.

7-15

From the DRAW menu, choose Circle.

Left click at point 1, then type 2 and
Enter.
From the DRAW menu, choose Fillet.
Type .2 and Enter. Left click at points 2
and 3. Then right click to end the
command.

The part is now complete, and it should be

the exact same dimensions as the desired
part.
To cut the part, you would simply convert
it to cut paths, place it where you want it
on the table, and tell the machine to cut it.

7-16

Creating a Complex Dimensioned Part

Suppose you needed to
make the part shown at right
to the exact dimensions
given. If the drawing is not
already available in a format
that you can import, you can
draw it directly in
PlasmaCAM.

From the FILE menu, choose New (you

dont need to save your changes).
On the VIEW menu, make sure that
Snap to NodePoints is checked, and
that Snap Orthogonal and Snap to Grid
are unchecked.
From the DRAW menu, choose Circle.
Type 1.55 and Enter, then left click
at point 1.
From the VIEW menu, choose Zoom
Window. Left click at points 2 and 3.
From the DRAW menu, choose Arc.
Activate Center Snap. (Access the
snaps by pressing the middle mouse
button, the key on the keyboard, or
just the letter shortcut for the snap.)
Left click at point 1, then type 1.65
and Enter. Next activate Orthogonal
Snap (temporarily only) and left click
at point 2. Finally, type 60 and
Enter.

7-17

Press Spacebar to repeat Arc. Left

click at point 1, then type @2.5,0 and
Enter. Type 40 and Enter.
From the EDIT menu, choose Move.
Activate Endpoint Snap and left click
at point 2 (on the arc as shown).
Activate Endpoint Snap again and left
click at point 3.

From the DRAW menu, choose Line(s).

Activate Endpoint Snap and left click
at point 1. Then type <150,1.6 and
Enter. Right click to end Line(s).
From the EDIT menu, choose Copy.
Left click at point 2, then left click at
point 2 again. Right click to end Copy.
From the EDIT menu, choose Rotate.
Left click at point 2, then type 90 and
Enter. Choose Redraw Screen from the
VIEW menu.
From the EDIT menu, choose Scale.
Left click at point 2, then left click at
point 3. Type 1.3 and Enter.
From the DRAW menu, choose Circle.
Left click at point 3, then left click at
point 2.
From the DRAW menu, choose Line(s).
Activate Endpoint Snap and left click
at point 1. Then left click at point 2.
Right click to end the command.
From the DRAW menu, choose Circle.
Activate Center Snap and left click at
point 1. Left click at point 3.
From the EDIT menu, choose Rotate.
Left click at point 3, then type 180
and Enter.
From the VIEW menu, choose Redraw
Screen.
From the EDIT menu, choose Scale.
Left click at point 3. Activate Center
Snap and left click at point 4. Then
type 2.75 and Enter.
7-18

From the DRAW menu, choose Arc.

Left click at point 1. Next type @0,2 and Enter. Then type 90 and
Enter.
From the EDIT menu, choose Move.
Activate Endpoint Snap, and left click
at point 2 (on the arc). Then activate
Quadrant Snap and left click at point 3.

From the EDIT menu, choose Rotate.

Activate Center Snap and left click at
point 1. Then type -60 and Enter.
From the EDIT menu, choose Trim.
Left click at point 2 (you may have to
click twice). Right click to end the
command.
More of the arc may be trimmed away
than you intended. If so, the two arcs
that are very close together do not
actually intersect. In such a case, you
should draw a temporary line to define
the intersection point. Follow the
instructions below:
Choose Undo from the EDIT menu.
From the DRAW menu, choose Line(s).
Activate Center Snap, and left click at
point 1. Activate Center Snap again
and left click at point 2. Right click to
end the command.
From the EDIT menu, choose Trim.
Left click at point 3. Right click to end
the command.
Select the two upper extra lines (left
click at point 4; then hold Ctrl and left
click at point 5). Choose Delete from
the EDIT menu.

7-19

Select the big circle and arc (hold Ctrl

and left click at points 1 and 2). From
the EDIT menu, choose Copy. Left
click anywhere on the screen, then type
@0,0 and Enter. Right click to end
the command.
From the EDIT menu, choose Offset.
Type .4 and Enter. Left click at
points 1 and 2, then right click to end
the command. From the VIEW menu,
choose Redraw Screen.
From the DRAW menu, choose Circle.
Activate Intersection Snap and left
click at point 1. Then activate
Perpendicular Snap and left click at
point 2.
Select the two new construction arcs
(hold Ctrl and left click at points 3 and
4). From the EDIT menu, choose
Delete.
From the EDIT menu, choose Trim.
Left click at points 1 through 4, then
right click to end the command. If any
unexpected parts are trimmed away,
use Undo and then create construction
lines for Trim as just shown. (Draw
construction lines between arc centers
to form solid intersection points.)
Select the extra construction shapes
(left click at point 5; then hold Ctrl and
left click at points 6 and 7 and others).
From the EDIT menu, choose Delete.
Select everything in the drawing (you
can use Select all By from the VIEW
menu). From the EDIT menu, choose
Link Segments.
Notice that when you unselect the
drawing, both the perimeter and the
hole of the hook are purple, indicating
that they are each closed loop paths.
From the FILE menu, choose Save.
Type Hook and click SAVE.
7-20

Nesting Parts and Preparing for Cutting

This example uses the hook drawn from the previous example, which instructed you to save the
drawing. If you saved the hook, you can load it by choosing Open from the FILE menu. Find
and select the file, then click the Open button.
On the VIEW menu, make sure that Snap to NodePoints is checked, and that Snap Orthogonal
and Snap to Grid are unchecked.
From the MACHINE menu, choose Convert to Cut Path and click just outside of the hook
perimeter where you would want the pierce point to be located.
From the VIEW menu, choose Zoom
Extents, then choose Zoom Out.
With everything selected, choose Copy
from the EDIT menu. Left click at
points 1 and 2, then right click to end
the command.
Notice that the original is still selected,
not the new copy. To have the copy
selected instead, you can choose Undo
then Redo from the EDIT menu.
From the EDIT menu choose Rotate.
Left click at point 3; then type 180
and Enter.
From the EDIT menu, choose Move.
Left click at points 1 and 2. (The goal
is to position the second hook inside of
the first without them intersecting).
Drag a selection window around
everything, so that both hooks are
selected. From the EDIT menu, choose
Rotate. Left click at point 3. Activate
Tangent Snap, then left click at point 4.
Type 0 and Enter.
Press Spacebar to repeat Rotate.
Activate Quadrant Snap and left click
at point 1. Activate Tangent Snap and
left click at point 2. Type 0 and
Enter.

7-21

From the VIEW menu, choose Zoom

Table.
From the EDIT menu, choose Move.
Activate Quadrant Snap and left click
at point 1. Activate Table Edge Snap
and left click at point 2 (on the edge of
the cutting area).

Press Spacebar to repeat Move.

Activate Quadrant Snap and left click
at point 1. Activate Table Edge Snap
and left click at point 2 (on the edge of
the cutting area).
From the VIEW menu, choose Zoom
Extents. Then choose Zoom Out.

From the EDIT menu, choose Copy.

Left click at point 1. Activate
Orthogonal Snap and left click at point
2 (position the copy so that it lies just
above the original). Activate
Orthogonal Snap again and left click at
point 3 (position the copy so that it lies
just to the right of the original).

From the DRAW menu, choose

Rectangle. Left click at points 1 and 2
(on the pierce points of the holes, even
if they are not oriented as shown).
From the VIEW menu, choose Zoom
Extents.
Select the four hook copies just made
in the previous step. From the EDIT
menu, choose Delete.

7-22

Select all parts of the hooks, but not the

rectangle (drag a selection window).
From the DRAW menu, choose Array.
Make sure that Rectangular is
checked. Type 5 at Number of
horizontal copies and 7 at Number
of vertical copies. Next click the OK
button. Left click at points 1 and 2.
Select the construction rectangle press
Delete.
From the VIEW menu, choose Zoom
Table.
Notice that a large number of hooks are well arranged for cutting:

7-23

Importing and Converting a Drawing

From the FILE menu, choose New; then choose Import. Make sure that Autocad DXF files is
chosen from under Files of type. In the directory \PlasmaCAM\Samples, find and select the
file Side Plate.dxf. Then click the Open button.
Drag a selection window around the
shape within the drawing (drag from
points 1 to 2). From the EDIT menu,
choose Move. Left click at point 3 and
then at point 1 to move the shape out of
the drawing block.
Drag a selection window around the
drawing block, from point 4 to point 5.
From the EDIT menu, choose Delete.
From the VIEW menu, choose Zoom
Extents.
Drag a selection window around the
entire shape, from points 1 to 2. From
the EDIT menu, choose Link Segments.
From the MACHINE menu, choose
Detect Intersections. Notice that
thousands of intersections are found.
From the VIEW menu, choose Zoom
Window. Zoom in to closely examine
the part perimeter (left click at points 3
and 4, repeat the command as needed).
Under close examination the shape
appears very crude, with multiple
overlapping jagged edges and gaps
between pieces.
From the VIEW menu, choose Settings
(or press Tab). Change Gap distance
to jump to 0.01. Change Delete
overlapping segments within to
0.005.

7-24

From the VIEW menu, choose Zoom

Extents.
From the EDIT menu, choose Undo
(take back Link Segments).
Choose Link Segments from the EDIT
menu.
From the MACHINE menu, choose
Detect Intersections. Notice that only a
few intersections remain.
From the VIEW menu, use Zoom
Window to magnify the area of
heaviest intersections (point 1).
You can see that this path is one piece even though it intersects itself. From the VIEW menu,
choose Zoom Extents.
Select the troublesome hole and also the perimeter (left click at point 1; then hold Ctrl and left
click at point and 2). Notice that the status bar reads 2 paths are selected. From the EDIT
menu, choose Explode. Now the status bar reads something like 1203 paths are selected.
Everything selected has been converted into individual line segments.
From the EDIT menu, choose Link Segments. Now everything is formed into complete closed
paths that are free of intersections. Although the shape is now properly joined together, you may
have noticed that it is still made up of dense rough edges. If you select everything, the status bar
reads 10 paths are selected (3897 nodes total).
From the EDIT menu, choose Smooth. Type .0007 and Enter. Now notice that the status bar
reads 10 paths are selected (362 nodes total). The number of nodes (and hence computer
memory) required to store the shape has been reduced by more than 90%. The new smoothed
shape is accurate to the original shape within 0.0007 inch (or whatever else you enter). Smooth
also removes fine choppiness as it simplifies shapes. You will notice the improvement if you
zoom in for a close look at any of the circles or arcs.
To prepare the part for cutting, choose Convert to Cut Path from the MACHINE menu (make
sure nothing is selected first). Left click just on the outside edge of the perimeter where you want
the cut to begin. The entire shape should be converted to cut paths.
Use Cut Preview from the MACHINE menu to see how the part will cut (click the OK button to
preview).
Remember to change the linking settings (under Settings from the VIEW menu) back to what they
were previously. Change Gap distance to jump to 0.005 and change Delete overlapping
segments within to 0 to disable.

7-25

Importing and Converting a Picture

From the FILE menu, choose New; then choose Import. Make sure that Bitmap files is chosen
from under Files of type. In the directory \PlasmaCAM\Samples, find and select the file
Cannon.bmp. Then click the Open button.
A dialog box appears showing a preview of the cannon picture. (This file was made by scanning
an actual photograph in black & white or line art mode.) Select white as the background color
either by left clicking the white button or by left clicking over the white area of the preview.
Click the Next button.
Enter 10 both at Hole width and Speckle width. Click the Next button. (A couple of minutes
may be required for the computer to remove spots from the image.)
Enter 0.75 at Smoothing (pixels), then click the Next button.
Select the obvious fragments to erase.
Drag a selection window from point 1
to point 2. Hold Ctrl and drag a
selection window from point 3 to point
4. From the EDIT menu, choose
Delete.
Select the entire shape by dragging a
selection window from one corner of
the screen to the other. To enlarge the
cannon to a length of about two feet,
choose Scale from the EDIT menu.
Left click at point 5 and at point 6.
Type 24 and Enter.
From the VIEW menu, choose Zoom Out.
From the EDIT menu, choose Move and move the shape so that it lies within the cutting area.
(You can type @2.5,3.5 and Enter for the second move point if you are not sure how to do
this.)
From the VIEW menu, choose Zoom Extents. Notice that some of the shapeespecially near the
top of the cannonconsists of many small broken pieces. This is because the top part of the
picture was somewhat fuzzy.
From the VIEW menu, choose Settings
(or press Tab). Change Gap distance
to jump to 0.08 and change Delete
overlapping segments within to
0.04.
Select the outlines that still appear
broken (left click at points 1 through 7
while holding Ctrl). From the EDIT
menu, choose Link Segments.

7-26

From the VIEW menu, choose Select All By. Check Open paths and uncheck Closed loop
paths. Click the OK button. You should notice from the status bar at the bottom of the screen
that nothing is selected. This is because no broken (open) paths are left in the drawing;
everything has been converted into closed loops.
Again choose Select All By. This time check Closed loop paths and press the OK button so that
the entire drawing is selected. From the VIEW menu, choose Select Shortest. You will notice
that the first item in the list is already selected. Likewise, the smallest apparent hole in the
cannon shape is shown in green, indicating that it is selected. You can experiment by selecting
other items from the list and watching as the corresponding shapes turn green in the drawing.
Select Shortest shows that there are no remaining little pieces left in the drawing that are not
supposed to be there. Click the OK button.
Again select the entire drawing and choose Smooth from the EDIT menu. Type 0.01 and Enter.
Repeat Smooth and again type 0.01 and Enter. Notice that much of the unwanted fuzz has
been removed from the image.
Use Zoom Window from the VIEW
menu to magnify the upper part of the
cannons main wheel.
On the VIEW menu, make sure that
Snap to NodePoints is checked, and
that Snap Orthogonal and Snap to Grid
are unchecked.
From the DRAW menu, choose Bulge.
Left click at points 1 through 3.
From the EDIT menu, choose Break.
Left click just to the left of point 1 and
just to the right of point 2. Right click
to end Break.
Select the fuzzy shape, not the new arc
just drawn (left click near point 3).
From the EDIT menu, choose Delete.
Select the new arc and choose Link
Segments from the EDIT menu.
From the VIEW menu, choose Zoom
Extents then Zoom Window to magnify
the front of the cannon barrel as shown.
Make sure that nothing is selected.
From the EDIT menu, choose Edit
Path. Left click near point 1. Then
press the Delete key. (This removes
the small glitch from the shape.)
Experiment with Edit by holding Ctrl
and pressing the arrow keys.

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From the VIEW menu, choose Zoom

Extents.
From the EDIT menu, choose Break.
Left click at points 1 through 4. Right
click to end the command.
Select the bottom pieces (left click at
point 5; then hold Ctrl and left click at
point 6. From the EDIT menu, choose
Delete.
Zoom in close to the bottom edge of
the cannon. Then free-hand draw some
realistic ground as shown using Line(s)
from the DRAW menu. (Right click to
end the command.)
Note that you can do zoom commands
during other commands by pressing the
keyboard shortcuts. Pan around the
drawing using the arrow keys. Also
experiment with F1 (Zoom Window)
and F4 (Zoom Extents) while you are
drawing in the lines.
The lines that you draw should connect exactly to the endpoints of the cannon perimeter (because
of NodePoint Snap), and the drawing should not contain overlapping lines or intersections
between linesonly what is required to complete the perimeter and lower hole as shown.
Before drawing the second point of the main bottom segment, activate Orthogonal Snap so that it
is drawn horizontal.
When you are done drawing the ground, select the new shapes and choose Link Segments from
the EDIT menu. The entire drawing should then be made up of closed paths, which are purple
(unselect everything).
Finally, choose Convert to Cut Path from the MACHINE menu. Left click just outside of the
perimeter where you want the cut to begin. The entire shape should be converted including all of
the holes.
Note, this example does not demonstrate the ability to recognize arcs during the smoothing of a
bitmap image. You may want to repeat this example, using arc recognition for a more rounded
image.
Remember to change the linking settings (under Settings from the VIEW menu) back to what they
were previously. Change Gap distance to jump to 0.005 and change Delete overlapping
segments within to 0 to disable.

7-28

Building a Computer Enclosure

Warning: Make sure that all of the instructions given in the previous chapters are followed
before you attempt to operate the cutting table.
This example project shows you how to build a filtered computer enclosure using the cutting
table and a sample file. In order to make this project, you will need basic tools including a socket
set and a box and pan brake. You will also need the following materials:
(1) 4ft by 10ft sheet of 20 gauge steel
(1) 25 by 29 piece of 10 gauge steel, optional (if you want to build the legs also)
(50) #10 by hex head self-tapping sheet metal screws
(2) 16 by 19 air conditioner air filters
(1) power strip (with surge suppresser)
(1) 110 VAC fan, part # CR126-ND from Digi-Key Inc. 800-344-4539 for $24.86, or like
(1) 110 VAC power cord (safely wire to fan)
This project is fairly complex and should only be attempted by those who are experienced with
sheet metal work and feel confident about building the project. Do not attempt the project until
after you have become fairly familiar with the software and how to operate the machine. Some
of the part geometry may have to be adjusted if the enclosure is to house an unusually sized PC.
Cutting the Shapes
Follow the instructions given in CHAPTER 5 for setting the torch geometry and timing. Verify
that the kerf width of your torch is twice the number shown at Offset distance (1/2 torch kerf
width) under Drawing and Editing of Settings, from the VIEW menu. Also, the Torch
Location Adjustment must be correctly set under System Configuration.
From the FILE menu, choose Open. In the directory \PlasmaCAM\Samples, find and select the
file PC Enclosure.pcm. Then click the Open button.
All of the shapes needed to make the computer enclosure are carefully placed within a 4ft by 10ft
area. (Except the legs, which you should select and Delete if you are not going to make them.)
Select the entire drawing. From the EDIT menu, choose Rotate. Type "24,24 and Enter. Then
type -90 and Enter. This places everything in the right orientation on the 5ft by 10ft cutting
surface (see drawing below).
Unselect everything in the drawing. From the VIEW menu, choose Zoom Table.
From the MACHINE menu, choose Convert to Cut Path. Left click just outside the perimeter of
each of the upper six shapes, where you want the pierce points to be located. Use the zoom
commands as necessary (even during Convert to Cut Path). When converting, be careful not to
click inside the edge of a perimeter; this will cause the shape to be offset toward the inside.
The shapes should all be blue now when not selected, including the holes. This signifies that the
shapes are now actual cut paths. From the FILE menu, choose Save As to save the drawing as a
new, temporary filename (otherwise you may overwrite the original file).
Position the sheet of metal on the cutting table, against the grate stops so that the upper shapes
are cut out of the upper end of the sheet as shown on the computer screen (see figure below).

7-29

grate stops
4x10 sheet

When the machine is ready, select all of the shapes and choose Cut from the MACHINE menu.
(Drag a selection window around the shapes; this will also select the holes which have to be cut
first.)
Bending the Shapes
Notice that most of the shapes have small grooves cut in various places along the edges. These
grooves indicate where the bends need to be made. Use a box and pan brake to bend all of the
pieces as required (90 degrees with 1/16 inch radius on all bends). The following illustrations
show what the parts should look like after bending (except the two back panels, which are not
bent):
Keyboard Shelf

7-30

Keyboard Duct

Filter Bracket (2)

CPU Door

7-31

Top Cover

Middle Shelf (2)

Fan Shelf

7-32

Main Cabinet

Optional Legs (4)

7-33

Assembling the Shapes

Keyboard Shelf
Screw together the two halves of the external keyboard shelf as shown below using four screws,

B
D
A

7-34

driven through the holes at A, from the outside. Then screw the shelf to the main cabinet with
four screws that are driven into the shelf from the inside of the cabinet, near B. The shelf should
now be firmly attached to the cabinet.
Filter Brackets
Screw the two filter brackets to the inside bottom of the cabinet, as shown. Each bracket is held
by two screws, driven in from the outside of the cabinet.
Inner Shelves and Door
Bolt the fan (at C above) to the lower fan shelf as shown. (The fan should already be safely
wired to a power cord.) Screw the fan shelf in place inside the cabinet using four screws that are
driven in from the outside of the cabinet, at the sides.
Set the sliding door (at D above) in place and screw in the two middle shelves using four screws
each, driven in from the outer sides of the cabinet. Note that the door must be properly
positioned before the shelves can be installed. You may also need to insert your computers CPU
before putting in all of the screws for the top shelf (paint everything first if this is the case).
Screw in the top cover using six screws that are driven in from the outside of the cabinet, at the
sides and front.
Back Panels
Screw the lower back panel to the cabinet and fan shelf as shown below using six screws (the
lowest holes are reserved for the optional legs).
The main back panel is held in place and made easy to remove as shown below by eight screws
which are driven only about half way into the back of the cabinet. The installed panel can be
removed simply by lifting it and pulling it off of the enclosure.
Legs
The optional legs can be attached to the main cabinet using four screws each. These screws are
driven through the legs and into the 16 lowest holes on the cabinet and lower back panel. If the
legs are not built and installed, the cabinet can simply rest on a table.
Finishing the Cabinet
When you are done assembling the cabinet, paint the outside of it.
Install your computer on the inside, carefully routing the wires through the holes that are
provided. The keyboard shelf has been designed to hold both a standard keyboard and a mouse
pad. The slot in the main back panel allows the power cords and parallel port cable to exit the
cabinet.
Attach the power strip to the side of the cabinet using double-stick foam. You can use the power
strip to switch on the computer, monitor, cabinet fan, and cutting table all at the same time.

7-35

7-36