Design Element | Suggestions (Industry Standard Values) | Reasons and Benefits |
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Material Thickness | Recommended range: 3 - 40 mm (ideal 5 - 25 mm) | Provides efficient cutting, acceptable accuracy, and minimal distortion. |
Hole Diameter | Minimum hole diameter ≥ 1.5x material thickness | Ensures clean edges, roundness, and reduces taper or distortion. |
Hole Spacing | Minimum spacing ≥ 1.5x material thickness | Maintains structural integrity and prevents warping or distortion. |
Minimum Feature Size | Minimum recommended width ≥ 2 mm | Ensures accurate cuts, minimizes distortion, and maintains feature stability. |
Kerf Width (cut width) | Typical kerf width: 1.5 - 3.5 mm | Accounts for material removal, ensuring dimensional accuracy and fit. |
Corner Radii | Minimum corner radius ≥ 1 - 2 mm | Reduces thermal stress, prevents cracking, and improves part durability. |
Text and Logos | Minimum height ≥ 15 mm | Ensures readability and clarity, considering plasma cut roughness. |
Tolerances | Typical dimensional tolerance: ±0.5 - 1.5 mm | Reflects achievable accuracy with plasma cutting; tighter tolerances increase cost. |
Edge Quality | Typical roughness: Ra 12.5 - 25 µm | Reflects inherent plasma-cut surfaces; suitable for general-purpose parts, or secondary finishing may be required. |
Tabs and Bridges | Recommended width ≥ 3 - 5 mm if necessary | Keeps parts secure during cutting, prevents shifting or dropping. |
Part Nesting and Spacing | Minimum spacing between parts ≥ 5 mm | Reduces thermal distortion, improves part accuracy, and simplifies handling. |
Sharp Corners | Avoid sharp corners, or add small radii (≥ 1 mm) | Minimizes localized overheating, warping, and stress concentration. |
Bevel/Angular Cuts | Limit bevel angle ≤ 30° (when possible) | Minimizes distortion and ensures edge quality and accuracy. |