While CNC shape cutting machines can use several different cutting processes, plasma cutting is by far the most economical.  CNC plasma can cut shapes in steel up to several inches thick.  However, such capacities are beyond the capabilities of the average small shop system.

The bevel plasma produces in the cut face makes it most useful on material up to approximately 3/8″ thick.  There are plasma cutters advertised as “high definition” units that improve on this, but we will focus on steel that thickness or less.

Generally speaking, the thicker the steel being cut, the greater the space required between features in the shape.  A certain amount of distance must be maintained between lines, internal shapes, and the outside profile.  This prevents components within the piece from overlapping or unexpectedly falling out.

Plasma cut shapes generally fall into one of two categories, i.e., industrial shapes and decorative shapes.  Industrial shapes consist of flanges, brackets, and other structural pieces designed for industrial use.

Some decorative shapes are pieces solely designed to represent some sort of object with visual appearance being the main purpose.  Of course, the two types can be combined to produce attractive items that serve a practical purpose.  Examples are weathervanes, mailboxes, house numbers, signs, etc.