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?
I actually haven't got the machine cutting properly yet, I think there is something badly wrong with the nozzle, the plasma jet comes out at like a 20 degree angle from the nozzle.
Tilting the torch over corrects for this but potentially there is still not enough focused energy in the cut.
I have new consumables coming soon and if they don't solve it then I don't know what to do. I could buy a new torch but don't necessarily want to. It can cut through 5mm steel in its present state, it's just slow and messy, but maybe good enough for what I need.