- Export the nested sheet from Zorocut as DXF (profile R2000, mm)
- Import it in SheetCAM at the drawing origin and give each ZC_ layer its own operation
- Post-process to your controller's G-code and run it there
Why not straight to the controller
Langmuir's staff state that CAD files such as .dxf cannot be opened directly in FireControl; it loads G-code. Mach3 and LinuxCNC tables are G-code controllers too. Something has to turn contours into toolpaths with lead-ins, kerf offset and pierce delays, and that is the CAM program's job — SheetCAM or Fusion — not the nester's.
SheetCAM, layer by layer
- SheetCAM applies each operation to everything on a layer, so one layer per operation is the contract. Zorocut's fixed layers fit it: a contour cut with outside offset on ZC_CUT, a low-current mark on ZC_MARK, an open-path operation without offset on ZC_ENGRAVE, and nothing on ZC_SHEET.
- Import with the drawing origin as the position: Zorocut puts the sheet's lower-left corner at 0,0, so the nest lands where it was planned.
- SheetCAM joins ends within its import link tolerance, fits arcs to runs of lines and drops tiny segments; its manual warns against using the tolerance to make up for a poor drawing. Zorocut's DXF has identical end points, so there is nothing to join.
- Text must be lines in SheetCAM. Zorocut's part labels are text on ZC_LABEL: give that layer no operation, or switch labels off.
Starting values from the Hypertherm chart
For a Hypertherm Powermax45 XP on mild steel with air, the manufacturer's chart gives these values. Zorocut uses the Best Quality speed and the pierce delay plus 0.2 s (the margin a Langmuir forum user adds for controller lag) as its plasma starter values. Hypertherm measured them with new consumables: calibrate with your own cuts.
| Thickness | Best Quality | Production | Pierce delay | Kerf |
|---|---|---|---|---|
| 3 mm | 3960 mm/min | 5590 mm/min | 0.2 s | 1.4 mm |
| 6 mm | 1430 mm/min | 2110 mm/min | 0.6 s | 1.5 mm |
| 10 mm | 780 mm/min | 920 mm/min | 0.8 s | 1.7 mm |
| 12 mm | 540 mm/min | 690 mm/min | 1.0 s | 1.7 mm |
| 16 mm | 310 mm/min | 400 mm/min | edge start | 2.1 mm |
The chart's pierce height on this torch is 3.8 mm. Hypertherm defines the Production speed as 80 % of the maximum speed rating: more parts per hour, not necessarily the best edge. The Powermax45 XP's pierce capacity is 12 mm, so thicker plate is started from the edge.
Sources
- Langmuir Systems forum, Files will not load (FireControl and DXF), 2023-08-11
- SheetCam TNG Setup and Operation Manual v3.1.17
- Hypertherm, Powermax45 XP/65/85/105 Cut Charts Guide 811300MU (cartridge, Duramax torches)
- Hypertherm, Powermax45 XP product page (capacity)
- Hypertherm, Powermax65/85 Operator Manual 806650 (cut chart definitions, consumable life)
- Langmuir Systems forum, Hypertherm 45 XP consumable life expectancy
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