Using a plasma cutter is very convenient and fairly easy. The benefit is that "freeform" cuts can be made to metal based on guiding the cutter. Since this machine works by directing plasma through the creation of a circuit, a ground clamp is necessary, much like welding.

This instructable is strictly to show practical operation of a plasma cutter. For an example where this operation is demonstrated to make something, refer to Sheet Metal Flower to Practice Plasma Cutting and Welding.

I made this at TechShop Detroit (www.techshop.ws).

Step 1: Choose Work Location

Since we plan on cutting metal, placing the metal on a surface that is safe and allows for freedom of movement is critical. A "grate" or similar surface that functions as a table is perfect.

Step 2: Plug in Unit

Ensure that the unit is off and plug it in.

Step 3: Connect the Air

Connect the external air compressor to the plasma cutter. This is to ensure that the stream of plasma remains under high pressure. To attach the fittings, recede the outer flange of the female connection and insert the male connection.

Step 4: Turn the Air On

Turn on the air flow. In this case, turn the lever ninety degrees from perpendicular to the air line to inline.

Step 5: Attach the Ground Clamp

Set the metal that you are using on the table and attach the ground clamp close to where you will be cutting.

Step 6: Turn on the Machine

Turn on the machine by flipping the switch behind the unit into the ON position.

Step 7: Set the Current

In this case we will set it to 25 for 18 ga sheet metal.

Step 8: Cut the Metal

Use the trigger on the gun to activate the plasma cutter. Note the trigger has a safety that must be lifted before you can depress the trigger. Keep the cutter (nozzle end) close to the metal and use the guide surrounding the nozzle to trace templates if you have them.