Nice build. There's been a lot of momentum in the desktop wire EDM community too, with projects like picoEDM, Gedm, openEDM, and baxEDM. Precision is the usual weakness of plasma cutting, but I suppose it makes up for that in speed. Have you tried tuning for kerf width or taper, or is that more trouble than it's worth at this scale?
What you all think about this one - https://youtu.be/wX-ivETq0nw ?
Expected to read about making the plasma cutter component, but it isn't - it's about the CNC component and the plasma cutter is off the shelf
Potentially easier solution for the USB problem: measure your cables with a DMM until you find one with good end-to-end shield continuity. A large proportion of USB cables have no effective common-mode protection (to say nothing of EMI shielding) because one end or both ends is ungrounded.
slag, cut taper, leadins and warping affecting surface level are all constant annoyances with plasma. I find it a lot easier to just send jobs to a waterjet shop nearby.
my friend did a lot of bulk plasma cutting, and his solution was to build a tumbler filled with abrasive and dish soap, and after a day or so the edges would be smooth and rounded. but that's certainly not a replacement for machined parts.
Reminds me of this startup in Germany: pilotarc.com