Interview with “Cappie”- cutting with the Powermax45 SYNC

Below is an interview with Jared “Cappie” Capp, who shared how the Powermax45 SYNC^® has supported his unique business. Known for his hit show on the Magnolia Network—a channel dedicated to home construction and renovation—Cappie and his daughter Alex regularly use Hypertherm Powermax plasma systems in their projects.

Q: How did you get the name Cappie?

A: My given name is Jared Capp, but everyone calls me Cappie. It was a nickname I got when I was in the US Air Force. It was the call sign on the airplane that I flew on. I’ve gone by Cappie my whole adult life. The only people that call me Jared, are my mom and my wife when she’s mad at me. Now, I'm the owner, operator, and president of Pangea Design Group based out of Spearfish, SD.

Q: Can you describe your company?

A: We are a full design-build service company specializing in the unique. In fact, the weirder, the better. We build a variety of structures ranging from outdoor living spaces to completely off-grid luxury homes and everything in between. We push the envelope of design and construction, aiming to bring more art into building. I like that I'm able to control my builds, do what I want, and incorporate a little art into it.

Q: What kind of projects do you typically work on?

A: It's a wide variety of customer projects, from custom garden gates to full-size houses with custom hand railings and everything in between. I really enjoy working with people who want to dream a little bit and give me some creative license.

Q: Do you also do any work with commercial customers?

A: Yes, we work with both residential and commercial customers, which has been great. My company started working mostly in the residential space, and I developed skills and collected tools like plasma cutters, and other specialty tools that made it possible to expand my skill set. We started to dip our toe into commercial projects, where people would call and want some custom feature piece or unique build out. These projects gained enough attention that we were pursued by numerous production companies, eventually landing us our own TV show on the Magnolia Network (also streaming on Max and other popular platforms) called Building Outside the Lines. My 16-year-old stepdaughter is the co-host of the show, and we turn things that were once junk into something amazing. For example, we did a big project with a 24-foot-tall steel water tank from the oil field, which we cut down using the plasma cutter and turned into a two-story art studio, complete with HVAC and Wi-Fi.

Q: Can you describe what type of cutting you typically do?

A: A lot of my work involves complicated cuts and cutting pieces off something that already exists. We cut a huge range of thicknesses and materials. We're starting to use robotic CNC arms with the Hypertherm plasma cutter because we needed a more precise way to cut rather than freehand. This is especially useful when I need to cut multiples of the same type of part, like numerous steel brackets that all match. The robotic arm made by CN-Seamless and plasma technology of the Powermax make it possible for me to create multiples of unique parts as well. I always tell my guys, “If you're going to make more than four of anything, you should have a template for it.” Now, I have the equivalent of a CNC table in a shop that I can take with me wherever I need to go, along with my Powermax45 SYNC. You just grab it, go, and with a little power and air, you're off and running, it’s been a game changer.

Q: What are the main benefits you look for when working with your plasma cutter?

A: My main priority is versatility. There are different ways to do things with the various types of cartridges. The versatility of the Hypertherm plasma cutter means I can use it in the shop on the bench or take it with me fifty miles into the woods. I'm not constrained by it. I can cut both thin and thick materials. We've had situations where we needed to cut through a mooring chain for a ship with 50 mm (2-inch) thick links. This was a remote project and moving the chain was not an option. Versatility is the key for me.

Q: What did you use before Hypertherm plasma?

A: I used grinding wheels and saws, like a lot of them, which was a very rudimentary way to do it. There was an evolution in my building and artistic processes. I started with simple, smaller, and thinner projects and then moved into the structural world, where we had to deliver what an engineer specifies. Because everything we do is so one-off, it's hard to have that mass-produced in small quantities at a machine shop.

Q: What made you want to change your method of cutting?

A: I switched from basic tools like grinders and saws to plasma cutting because it gave me more opportunities to be artistic, as well as move into thicker gauge materials. On a recent project, I was cutting doors off a shipping container to replace them with a glass roll-up garage door. The doors were welded in place, so we had to physically cut the hinges off to remove them.

Q: Can you talk a little bit about how Powermax has helped you in your business?

A: The first Powermax I had 15 years ago was the non-SYNC version, and I've since upgraded to the Powermax45 SYNC. The learning curve with the Powermax SYNC is shorter, which is great for teaching younger people and interns who have never used this kind of equipment. It can be intimidating, but I can show them what it's supposed to feel like, giving them confidence. We talk a lot about "time on stick" – just a little time using the tool to get comfortable with it. Efficiency in any business is where the profit margin lives. The more efficient, the better the profit.

Q: How has using the Powermax cartridge changed how you work?

A: When I used the five-piece consumables, I had a tackle box with all the parts. It was like playing "pick your part" on the table with big gloves on. With the new machine, changing a tip is quick and easy, and in 15 seconds, I'm back to cutting. Time is the most expensive thing on a job site. The cartridges last a long time, and I was impressed with their durability. My business has changed since I started using Powermax. The new technology has opened up possibilities, clients, and opportunities for me. It's about offering the best product for my clients and showcasing my best work while making it affordable.

Q: Can you talk a little bit about your daughter Alex and how she started plasma cutting?

A: Alex has always been very artistic. Even as a little kid, she loved drawing and painting. When Alex and I spent time together, she'd come to work with me in the shop. I would do what I needed to do, and I would let her do something with the torch. I remember her eyes lighting up because of the sparks flying and bouncing off the concrete floor. I clamped a piece of plate to the table at her height, and she drew circles, hearts, and squiggly lines. She just got used to doing it. I've taught Alex many different things, from welding and cutting to driving heavy equipment. She can drive skid steers and excavators, and she's also a ballerina. She has a huge spectrum of skills, which makes me very proud. Cappie's journey with the Powermax45 SYNC^® has not only enhanced his business but also allowed him to push the boundaries of creativity and efficiency in his projects. His story is a testament to the power of innovation and the impact of the right tools in the hands of a skilled artisan.