An improvised CNC plasma cutter was built around an inexpensive Parkside PPS 30 B2 with high-frequency (HF) arc start. Igniting the arc repeatedly disconnected the USB link between UGS and the Grbl motion controller, but Grbl kept following movements already buffered in memory. The solution was to replace USB control with FluidNC on an ESP32 and communicate over Wi-Fi. A homemade board adapted the ESP32’s 3.3-volt outputs for the machine’s 5-volt signals, and a relay connected to the torch trigger lets G-code switch the arc on and off. The experience suggests choosing a blowback-start cutter when possible, but shows that Wi-Fi can make an HF-start machine usable for CNC.
The motion platform combines steel box section, GT2 belts, 3D-printed parts and bearings running directly on the steel; it has some unwanted play, but the author considers its modest accuracy adequate because plasma cutting places little load on the machine. Leadshine servos worked despite being powered below their documented minimum voltage, though their alarm inputs falsely triggered during arc starts, reinforcing the recommendation to avoid controller inputs near HF interference. Cutting proved harder than expected: 4 mm steel produced poor results, while a 3 mm heart-shaped test cut succeeded after the compressor was moved to a separate electrical outlet. The cut had slag and bevel, possibly due to worn torch consumables or alignment. The main lessons are that simple belts and printed construction can suffice, while tuning cutting settings and managing electrical interference remain challenges.
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