A bolt-together CNC plasma tube cutter for round, square, and rectangular tubing.
Build documentation, manufacturing files, wiring diagrams, and component lists. Software is not included.
Offline Windows software for conversational G-code generation and machine control.
Machine plans and Windows control software in one purchase.
Mr. Gusset is a builder-assembled, four-axis CNC plasma tube cutter for round, square, and rectangular tubing. The structure is completely bolt-together and uses standard fasteners throughout, so the machine can be assembled without welding the frame.
The tube is carried by the chuck system while the cutting head moves around it. The rear four-jaw chuck travels along the X axis to position the tube lengthwise. Y moves the torch laterally, Z moves it vertically, and U rotates the chuck and tube. Coordinating those four axes lets the cutting path move along the tube, across its faces, and around its circumference.
The rotary U axis is what allows one setup to reach multiple faces of square and rectangular tubing and the circumference of round tubing without removing and manually repositioning the workpiece between cuts. Manual U jogging is displayed in degrees; during a cutting job, the rotary motion is calculated from tube surface distance.
Mr. Gusset can produce common fabrication features such as holes, slots, notches, cope cuts, repeated patterns, and cuts placed on multiple sides of a tube. These are the kinds of features that otherwise require repeated measuring, marking, drilling, plasma cutting, grinding, and test fitting when produced manually.
A tube is loaded and clamped in the chuck system, then the machine positions and rotates the workpiece as the torch follows the programmed path. This is particularly useful when a part has several features or when the same geometry needs to be produced more than once, because the cutting sequence can be repeated without laying out every tube by hand.
Built for small fabrication shops, chassis work, prototyping, hobby fabrication, and low-volume production.
U-axis: Manual jogging is displayed in degrees. During a cutting job, rotary movement is calculated from tube surface distance.
| Chuck configuration | Adjustment | Supported dimensions |
|---|---|---|
| Imperial chuck | Fixed locating positions | 1, 1.5, 2, 2.5, and 3 in |
| Metric chuck | Fixed locating positions | 30, 40, 50, 60, and 70 mm |
| Adjustable chuck | Sliding adjustment | Continuous adjustment from 1–2.5 in (25.4–63.5 mm) |
All chuck configurations support round, square, and rectangular tubing. For square and rectangular tube, the listed dimensions can be combined independently; for example, 1 × 3 in rectangular tube with the imperial chuck.
| Machine footprint | 94.5 × 25.2 × 25.2 in (240 × 64 × 64 cm) |
|---|---|
| Approx. assembled weight | ~130 lb (59 kg) |
| Recommended clearance | 43.3 in W × 133.9 in L × 25.2 in H (110 cm W × 340 cm L × 64 cm H) |
Create common tube cuts by entering dimensions directly into the software. No separate CAD model, separate CAM program, or file-transfer step is required for the conversational workflow.
The same application handles G-code generation, jogging, homing, graphical path review, cut-list management, project save/load, and job execution.
The desktop application is designed to run without an internet connection and is sold as a one-time purchase with no recurring subscription.
| Software details | |
|---|---|
| Conversational G-code | Enter tube dimensions and cut parameters for common operations. |
| Machine control | Jog, home, and run jobs from the same application. |
| Path viewer | Review the generated cutting path before running the machine. |
| Cut list | Build, edit, array, rename, and reorder operations. |
| Project files | Save projects locally and reload recurring work later. |
| Offline use | No internet connection is required for normal desktop operation. |
| Units | Imperial and metric. |
| License | One-time purchase; no recurring subscription. |
My name is Evan Jezek, and I am an experienced welder, fabricator, and designer with a degree in Welding Technology. My background includes custom chassis fabrication, motorsports, and defense manufacturing, where I have gained hands-on experience with both traditional fabrication and automated manufacturing processes. I am currently working toward a bachelor’s degree in Welding and Fabrication Engineering Technology at Pennsylvania College of Technology, and I am a proud member of my school’s Baja SAE team.
While I was finishing my associate degree, I got a job at a custom hot rod chassis shop. Most of the work we did involved fabricating and welding square and rectangular tubing. It was the kind of work I was interested in, but it did not take long for me to realize that the business was struggling.
We could not complete orders fast enough, and we did not have the equipment we needed to keep up with the workload. Nearly every tube had to be laid out and cut by hand. We would manually scribe cut lines and hole locations, then make the cuts using drills, handheld plasma cutters, and grinders.
It worked, but it was a slow and labor-intensive process. A large amount of time went into measuring, marking, cutting, grinding, and test fitting parts before they were ready to weld. When nearly every job required the same manual process, it became difficult for the shop to complete work quickly enough.
I knew there had to be a better way to produce these parts.
Industrial CNC tube-cutting systems already existed, but they were far outside what a small shop like ours could afford.
Instead of accepting that this kind of equipment was simply out of reach, I decided to try building my own affordable CNC tube-cutting machine.
That project eventually became Mr. Gusset.
My original goal was to finish the machine and use it in the shop to help us produce parts faster. Sadly, I was not able to complete it before the business closed its doors.
Even after the shop closed, I did not want to abandon the project. I had seen firsthand how much small fabrication businesses could benefit from this type of equipment and how difficult it was for them to afford the industrial machines already on the market.
I made a promise to myself that I would keep developing Mr. Gusset so it could eventually help other fabricators avoid the same problems.
Since then, I have continued building my skills in fabrication, machine design, automation, CNC equipment, and industrial robotics. After earning my associate degree, I continued my education in Welding and Fabrication Engineering Technology while developing Mr. Gusset into a complete machine, plan package, and software system.
I designed Mr. Gusset to bridge the gap between slow manual fabrication and expensive industrial machinery. The machine is completely bolt-together, making it more practical for small businesses and individual builders to assemble without needing the resources of a large manufacturing facility.
The software was developed around the same goal. Instead of requiring users to model every basic cut in CAD and transfer it through a separate CAM program, the conversational software allows fabricators to enter their tubing dimensions and cut information directly. The software then generates the G-code and controls the machine from one application.
Everything is designed to run locally on the user’s computer without depending on an internet connection.
Just as importantly, the software is a one-time purchase. I believe that when customers pay for a tool, they should be able to keep using it without monthly payments or annual renewal fees.
The goal of the business is to create practical and affordable automation tools for welders, fabricators, hobbyists, and small shops. These are people who can benefit from better equipment but are often priced out of traditional industrial automation.
Mr. Gusset was created because I watched a shop struggle day after day with slow, manual work that held everything back. Hedgehog Fabrication exists because I want to build the kind of tools that would have changed that situation and put them in the hands of people facing the same challenges.
Mr. Gusset is a do-it-yourself CNC plasma-cutting machine involving high voltage, automated movement, rotating components, pinch and crush points, plasma arc radiation, sparks, hot metal, fumes, noise, and fire hazards.
The purchaser is responsible for safely building, wiring, grounding, guarding, installing, testing, maintaining, and operating the completed machine. Only individuals with the knowledge and experience required to work safely with CNC machinery, electrical systems, and plasma-cutting equipment should build or operate it.
Use appropriate guarding, ventilation or fume extraction, fire-prevention measures, eye and face protection, protective clothing, hearing protection, and other PPE appropriate for plasma cutting. Never operate the machine unattended.
Disconnect and secure all energy sources before servicing, adjusting, repairing, or entering a hazardous area of the machine.
Hedgehog Fabrication does not certify that a customer-built machine complies with any specific workplace, electrical, fire, environmental, building, or machine-safety regulation. The purchaser and operator are responsible for requirements that apply to their location and use.
Cost estimate: The approximately $3,000 parts cost is an estimate. Actual cost varies with component pricing, shipping, supplier selection, plasma cutter selection, optional upgrades, taxes, and import charges.
Software delivery: Mr. Gusset software is delivered via email after purchase. Software is sold as a one-time purchase with no recurring subscription. Hedgehog Fabrication retains ownership of the software and its intellectual property; the customer retains the right to use the purchased version.
Plans delivery: Machine plans are delivered as a digital download. Included DXF files are manufacturing files for machine construction and do not indicate that the Mr. Gusset software supports DXF cut-profile import.
Build support: Build and assembly support applies to machines built using the official parts lists and controlled with the Mr. Gusset software bundle. Alternative controllers, software, wiring configurations, and integrations are outside that support scope.
Machine specifications: Published dimensions and weight shown here are for the standard 2000 mm rail build unless otherwise noted. Builder-selected rail length and configuration can change overall dimensions and assembled weight. Chuck capacities and axis specifications reflect the current design and may change in future plan revisions. Refer to the purchased plan version for construction details.