Should you combine a router with a CNC plasma table?

Some Powermax^® customers are considering adding a router to their plasma machine, and they ask for my opinion on it. Although there are OEMs that make plasma machines that include a router, I’m personally wary of this kind of combination system because the mechanics and motion of a router and the Powermax are very different. The CNC drive systems, motors, electronics, and z-axes needed for each process are not the same.  

CNC plasma tables

In industries like plasma cutting, automation produces higher-quality parts with consistent and repeatable results. People are not able to consistently and precisely repeat manual processes or repetitive tasks, and they make mistakes. Automated processes are infinitely repeatable and not subject to human error. CNC plasma tables increase efficiency, improve cut quality, and reduce material waste.

Handheld cutting requires extensive training and skill, while CNC plasma tables ensure precise cuts that are controlled by computers – making plasma cutting easier for operators with very little training. With proper training, a single technician can operate a CNC plasma machine and produce hundreds or thousands of precision cuts per day. With faster cutting speeds and precise automation, these machines enable workshops to produce more components in less time, decreasing labor requirements and labor costs while increasing productivity.

Since cutting is controlled by CNC controllers driven by precise CAD/CAM designs, automated plasma cutting is more accurate, significantly decreasing secondary work. This increased productivity leads to improved efficiency and profitability for businesses.

CNC plasma machines have advanced safety features to protect operators and minimize the risk of accidents. From automatic torch height control to safety interlocks, these machines prioritize operator safety without compromising cutting performance.

CNC routing tables

In certain industries and applications – such as aeronautics, automobile construction, or armaments – some parts cannot be cut using a thermal process to ensure the material does not deteriorate. The parts are machined using cutters that make it possible to route complex geometric shapes with great precision.

CNC routing replaces manual, hand-held routing with automation, delivering precise and timely cutting, reducing errors, and increasing efficiency. CNC routers automate the tool path route, providing more effective cuts compared to manual-controlled routers. They can perform large quantities of projects while operators are working on other tasks, increasing efficiency and reducing labor costs.

CNC routers are safer than manual routers. Routers can generate chippings and dust when cutting, but CNC routers often have a dust extraction system – consisting of a filter and an extractor fan – fitted to reduce the dust leaving the bed to the surrounding environment. This improves working conditions for operators.

With their computer-operated nature, CNC routers deliver better precision and consistency. Once the design and measurements are inputted into the system, the CNC router can create as many products as required. They can easily, accurately, and consistently repeat designs, so each product looks the same.

Unlike handheld machines that are prone to errors and inexact cuts, CNC routers are precise and reliable, efficiently using raw materials to reduce waste.

Advantages of combining a CNC plasma and CNC router on one table

The combination of a plasma cutter and a router on a CNC plasma table offers versatility, allowing manufacturers to switch between cutting and routing processes without the need for additional machines. This can save time and space in a workshop.

The combined machine can perform both plasma cutting and router operations on the same workpiece without moving the workpiece. This can also save time in the manufacturing process.

A plasma table primarily cuts metal. By adding a router accessory, the table can cut wood, plastic, and composites. Projects involving composite materials or laminates that require both cutting and milling benefit from having a router on a CNC plasma table.

Why the advantages may not be enough to justify a combined table

As previously stated, the mechanics and motion of a router and the Powermax are very different, requiring different CNC drive systems, motors, electronics, and z-axes.

A CNC plasma machine needs to glide with even motion. The torque of the drive motors must accelerate smoothly, but also quickly, to reach optimal cut speeds. Since the plasma arc is electrically charged gas, it melts metal, so it does not require a high tool-to-work torque. The heat of the plasma arc liquefies the metal and the secondary plasma gas blows the molten metal away from the plate.  

For CNC routing, it’s the total opposite. Often compared to milling, routers need high tool-to-work torque. These power tools can drill, bore, and cut multi-dimensional groves, but materials must be clamped down to the cutting bed. The force of the router can push or shift the material out of place. Since routing grinds away material, tool speed is just a fraction of what automated plasma requires.

Conclusion: Purchase two separate systems for the best results

If you choose a combo CNC plasma and router machine, you will usually compromise either the plasma system or the router. In some cases, both tools are compromised. Again, the drive motors, gear reductions, and material holding methods are different. My advice is to purchase two separate systems. You’ll gain improved system performance and reduce machine wear, and neither system will be in competition for cut time.

Learn how Powermax can help you get the most from your CNC plasma table.