How to Make Steel Cutouts
If you are creating an artistic figure or are in need of a custom metal shape for building, you may need to cut through steel. Making steel cutouts is somewhat challenging. However with the right tools --- including a plasma cutter --- you can slice through the strong material and create almost any shape you desire. Create a simple design such as a basic shape or letter if this is your first attempt at making a steel cutout.
Things You'll Need
- Steel, 18- to 26-gauge
- Permanent marker
- Rubbing alcohol
- Rag
- Metal table
- Clamps
- Metal sawhorse stands
- Leather gloves
- Long-sleeved shirt
- Pants
- Leather boots
- Eye protection
- Plasma cutter
- Deburring tool.
Instructions
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Select a piece of thin, 18- to 26-gauge steel from which you want to create the cutout.
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Sketch the design onto the steel sheet using a black permanent marker as it will be easy to see on the metal and won't rub off in the cutting process. If you make a mistake, remove the marked line with rubbing alcohol and a rag. Create a large design as bigger shapes are easier to cut out.
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Suspend the steel in the air above a nonflammable surface, such as a concrete floor. Suspend the material off the edge of a metal table using clamps or securely position it between two metal sawhorses.
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Put on leather gloves and eye protection.
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Turn on a plasma cutter, keeping the nozzle of the machine facing away from you. Place the nozzle of the plasma cutter about 1/8 inch above the surface of the steel, along one of the marked lines. Gently squeeze the trigger of the plasma cutter. The torch of the plasma cutter will slice through the material. Ensure there are sparks falling from the other side of the steel. This indicates that the steel is being fully penetrated. If you don't see sparks, hold the plasma cutter over the line a few seconds longer until the sparks break through the steel.
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Trace along the marked lines on the steel with the plasma cutter. Move slowly so that the plasma cutter can properly heat and cut through the metal. Release the machine's trigger when a line is finished. Reposition the steel so that you're always cutting away from yourself. Cut out the entire shape.
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Trace along the outside of the metal cutout with a deburring tool to slice any burrs and loose steel fragments away from the design. Move the tool along all of the cut edges of the steel to complete the project.
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Tips & Warnings
To guard against burns, wear a long-sleeved shirt, long pants and leather boots when making a steel cutout.
Keep all flammable materials away from the area when working with the plasma cutter.
Plasma cutters are very hot. Always use the proper safety gear when handling the device.
References
- Photo Credit Hemera Technologies/PhotoObjects.net/Getty Images
