The Road to Plasma-Cutting Automation

Fabricators note several reasons for considering the move from manual plasma-arc cutting (PAC) to automated cutting. For Mike Wagner, owner of Cornfield Customs Hot Rod, Loveland, OH, the reason to automate was simple: his customers deserved their quality cut parts at a reasonable price. His mission was to deliver.

Mike Wagner, a builder of hot rods since 2006, specializes in pre-1950 American-made cars. “We mainly like the 1926 to 1932 Fords,” he says. “We build the chassis inhouse, design all of the suspension setups, and fabricate most of the custom sheetmetal.”

“We mainly like the 1926 to 1932 Fords,” he says. “We build the chassis inhouse, design all of the suspension setups, and fabricate most of the custom sheetmetal.”

Hot-rod enthusiasts turn to Cornfield Customs for custom-built frames, frame and sheetmetal modification, turnkey cars, suspension systems, welding and fabrication, and CNC PAC. The bulk of Wagner’s plasma-cut parts include frame, chassis and suspension brackets and tabs for hot-rod assemblies including four-link rear suspensions, front-end mounts and motor-mount kits.

“Customers often specify my hand-cut parts,” says Wagner, “but I didn’t feel I could charge them for what it actually took to cut the parts. If, for example, I’m cutting brackets by hand and then I need to clean them, you’re talking two to three hours for a set of brackets. I can’t charge $150 or $200 for a set of brackets when customers can buy them on eBay for less.”

Purchasing the Right System

Wagner had reached his tipping point, but facilitating the transition to automation required a number of decisions. First, purchasing the right type of automated PAC setup required a complete understanding of how his applications would apply to automation—in dollars and cents. High-precision dual-gas cutting systems cost tens of thousands of dollars, often accompanied by an equally expensive controller. While these setups provide very high cutting speeds, it is difficult, if not impossible, for a small fabricator to justify such an investment.

Best-fitting Wagner’s needs: an air-shielded single-gas plasma system, which carries a price tag in the $3000 to $6000 range, depending on capacity.

“There’s no sense in buying a $40,000 machine to make parts if you can buy the parts for 10 cents more than it costs you to make them,” says Wagner.

For cutting the same shape multiple times, using an automated plasma table saves hours of post-cut grinding, which enables Cornfield Customs to maintain price competitiveness.

In addition to offering a cutting capacity of 18-gauge to 3⁄8-in. steel plate, the 60-A system can tackle 1⁄2-in. aluminum. 

“On 1⁄8- or ¼-in. material, the cut quality has been great, and I can cut superfast,” says Wagner at speeds to 110 in./min. The move to an automated system has increased productivity, and the machine produces good, clean cuts.” 

Further, Wagner notes a dramatic reduction in the amount of cut-edge finishing. “I usually can just knock the dross off the back and then take parts to the grinder to clean everything else off,” he says. 

“I didn’t decide to automate just to reduce costs,” says Wagner. “I knew it would make life easier around the shop. Now I can make my own brackets rather than outsource. Once I design a new bracket, 20 min. later I have the parts in my hand ready to deliver to the customer. There’s no need to call a supplier and wait a week for shipment, while paying more in the long run.”