The Ultimate Guide to Plasma Cutters (2025 Edition)

A plasma cutter is a machine that cuts conductive metals such as steel, aluminium, and copper. Using an electrical arc and compressed gas, it creates a high-temperature plasma jet. This melts the metal and blows away the molten material for a clean, fast cut.

If you work with metal, chances are you’ve heard of plasma cutters. But what exactly are they, how do they work, and why have they become a go-to tool across industries? From automotive repair to art work and heavy fabrication.

In this guide, we’ll walk you through everything you need to know about plasma cutters. From the basics of how they operate, to the different types of machines. As well as safety considerations, and what to look for when choosing one.

Whether you’re completely new to plasma cutting, exploring options for your workshop, or curious about the technology. This guide answers your questions in clear, practical terms.

With over 60 years of experience supplying welding and cutting equipment Worldwide, we’ve helped thousands of businesses find the right solution for their needs.

Drawing on that expertise, we’ve put together this guide to give you the knowledge and confidence to understand plasma cutting. Enabling you to decide if it’s the right fit for your projects.

Key Takeaways

• Plasma cutters use electricity and compressed gas to create a superheated plasma jet. This melts and cuts through conductive metals.
• They can cut a wide range of materials including steel, aluminium, stainless steel, copper, and brass. Thicknesses range from thin sheet to several inches.
• Popular across industries such as automotive repair, fabrication, HVAC, shipbuilding. Even metal art, thanks to speed and versatility of the process.
• Types of plasma cutters include industrial handheld, mechanised and CNC systems. As well as portable, smaller units for light-duty use.
• Choosing the right machine depends on factors like metal thickness, duty cycle and portability. Plus input power needs, and cost of consumables.
• Safety is essential. Always use eye protection, gloves, flame-resistant clothing, and ensure proper ventilation.
• Maintenance extends lifespan. Replace consumables regularly, keep torches clean, and check gas/air supply.
• Compared to alternatives; plasma is faster and more affordable than laser cutting for thin metals. Achieve greater precision and faster speeds than oxy-fuel on thicker sheets.

Contents

1. What is a plasma cutter?
2. How plasma cutting works
3. What can you cut? Materials & thicknesses
4. Types of plasma cutters
5. Choosing the right plasma cutter
6. Setup & operation basics
7. Safety essentials
8. Maintenance & consumables
9. Plasma cutter vs alternatives
10. Common FAQs
11. Real-world use cases
12. Conclusion & resources

What is a Plasma Cutter?

In summary, a plasma cutter is a machine that cuts conductive metals such as steel, aluminium, and copper. Using an electrical arc and compressed gas, it creates a high-temperature plasma jet. This melts the metal and blows away the molten material for a clean, fast cut.

More in depth, a plasma cutter is a machine that uses a jet of ionised gas to cut through electrically conductive metals. It’s one of the fastest, most efficient ways to shape and process metal, offering clean cuts with minimal effort. Especially compared to traditional methods like oxy-fuel cutting or mechanical saws.

At its core, the process works by creating an electrical circuit between the machine’s torch and the workpiece.

A compressed gas (usually air, nitrogen, or oxygen) is forced through a small nozzle. Then when the electric arc passes through it, the gas becomes superheated to more than 20,000°C.

This forms plasma — the “fourth state of matter” — which instantly melts the metal. While the high-velocity gas blows the molten material away to create a precise cut.

Why Plasma Cutting Matters

Plasma cutting has revolutionised the way industries work with metal, providing:

• Speed: Cuts metals faster than oxy-fuel or mechanical methods.
• Versatility: Suitable for a wide range of metals and thicknesses.
• Affordability: Modern units are compact and cost-effective for workshops of all sizes.
• Precision: Produces smooth edges with less need for secondary finishing.

Typical Applications

Plasma cutters are widely used across:

• Manufacturing and fabrication – cutting steel sheets, structural beams, and components.
• Automotive repair and customisation – removing damaged panels, cutting frames, or fabricating custom parts.
• Construction and HVAC – quickly shaping ductwork, pipes, and brackets on site.
• Artistic metalwork – creating sculptures, signage, and decorative features.
• Salvage and recycling – dismantling old vehicles, machinery, and scrap metal efficiently.

Plasma Cutting in Today’s Workshops

Once reserved for large, industrial facilities, advancements in technology have made them more accessible. Small businesses, independent fabricators, even DIY enthusiasts can now benefit from plasma cutting.

Portable models are light enough to carry on site. While CNC plasma systems offer automated precision for complex, repeatable cuts.

How does a plasma cutter work?

A plasma cutter works by sending an electric arc through a stream of gas, which is forced through a small nozzle. The energy turns the gas into plasma, creating a jet hot enough to melt metal. While the gas flow blows away molten material to form a cut.

Step-by-Step Process

1. Power Supply Activated
   • The plasma cutter connects to a power source. Either single-phase 110/240V or three-phase 400V depending on the machine.
   • This generates a high-voltage circuit between the torch and the workpiece.
2. Gas Flow Begins
   • Compressed air or a chosen gas (oxygen, nitrogen, or argon mixes) is forced through the torch nozzle.
   • The gas pressure ensures a narrow, concentrated flow ready to be ionised.
3. Arc Ignition
   • A pilot arc is struck inside the torch between the electrode and nozzle.
   • When the torch touches or nears the workpiece, the arc transfers. Completing the circuit.
4. Plasma Formation
   • The electric arc superheats the gas to over 20,000°C (36,000°F), stripping electrons and turning it into plasma.
   • Plasma is electrically conductive. Allowing it to maintain the cutting arc with the workpiece.
5. Cutting Action
   • The plasma jet melts the metal instantly.
   • The high-velocity gas blows away molten metal, leaving a narrow, clean cut.

The Key Components of a Plasma Cutter

• Power Supply: Converts AC into smooth DC for a stable cutting arc.
• Torch: Contains the electrode and nozzle that direct the plasma jet.
• Electrode & Nozzle (Consumables): Wear parts that shape the arc — regular replacement is vital.
• Ground Clamp: Completes the electrical circuit with the workpiece.
• Gas/Air Supply: Provides the compressed air or gas required for the plasma stream.

Why Plasma Cutting Works So Well

• High Heat Concentration: Plasma is hotter than the sun’s surface, allowing instant melting.
• Directed Jet: The constricted nozzle creates a narrow, precise cutting path.
• Dual Action: The jet both melts and ejects material. Speeding up cutting compared to methods like oxy-fuel.

Visualising the Process

Imagine plasma cutting as a super-heated, electrically charged “laser of gas.”

While a torch ignites the plasma, the combination of heat and pressure slices cleanly through metal. This balance of energy and airflow is what makes plasma cutting both powerful and efficient.

What can you cut with a plasma cutter?

Plasma cutters can cut any electrically conductive metal. Including carbon steel, stainless steel, aluminium, brass, and copper. They are most effective for sheet metal and plate thicknesses up to several inches, depending on the machine’s power.

One of the biggest advantages of plasma cutting is its versatility. This makes them a go-to tool in industries where speed, flexibility, and cost-efficiency are key.

Common Materials for Plasma Cutting

• Mild Steel (Carbon Steel)
  • Plasma cutters handle mild steel with ease, delivering clean cuts up to several inches thick (depending on machine power). It’s the most common application for a plasma cutter.
  • Suitable for fabrication, structural work, and general workshop use.
• Stainless Steel
  • Maintains corrosion resistance after cutting.
  • Often used in food industry equipment, architectural projects, and industrial piping.
• Aluminium
  • Plasma is ideal for aluminium, which is difficult to cut with oxy-fuel due to its oxidation layer.
  • Used in automotive repair, aerospace, and marine fabrication.
• Copper & Brass
  • Higher conductivity makes them trickier, but plasma can cut them effectively with the right gas settings.
  • Typical in electrical industries and artistic metalwork.
• Exotic Metals
  • Titanium, Inconel, and other alloys can also be cut. Making plasma valuable for specialised industries like aerospace and defence.

Thickness Capabilities

The maximum thickness you can cut depends on the power rating of the plasma cutter. The below chart can be used as a guide:

Machine Type	Recommended Clean Cut	Severance (max cut)
Light-duty (30–40A)	Up to 10mm (13/32″)	~16mm (5/8″)
Medium (40–80A)	10 – 32mm (13/32 – 1 1/4″)	~38mm (1 1/2″)
Heavy-duty (80–200A)	25 – 50mm (1 – 2″)	~75mm (2.95″)
Industrial CNC (>200A)	50mm+ (2″+)	160mm (6 1/4″)+ with specialised units

Tip from Craig Westerman: Manufacturers often state maximum severance thickness. But for production-quality results, always check the recommended clean cut thickness. Going beyond this may leave rougher edges and need secondary finishing.

*chart values taken from industry-leading Hypertherm plasma cutters.

Advantages Over Other Cutting Methods

• Plasma vs Oxy-Fuel: Plasma can cut stainless steel and aluminium (oxy-fuel can’t). It’s also faster on thinner metals.
• Plasma vs Laser: Plasma is more cost-effective for thicker metals. While laser excels at ultra-precise cuts in thin sheet.
• Plasma vs Mechanical Sawing/Grinding: Faster, smoother, and less manual effort.

Real-World Applications by Material

• Automotive repair shops. Plasma cutters slice through steel body panels and aluminium parts fast.
• Fabrication workshops. Invaluable for applications like structural steel beams and stainless steel components.
• HVAC installers. Portable plasma cutters are ideal for ductwork, sheet metal, and pipe cutting on site.
• Artists and designers. Easily cut intricate shapes in stainless, brass, or copper for sculptures and signage.

Types of Plasma Cutters

Plasma cutters aren’t one-size-fits-all. They come in a range of formats, from small handheld tools for light fabrication through to large CNC machines used in heavy industry.

Choosing the right type depends on the material thickness, precision required, and environment you’re working in.

1. Handheld Plasma Cutters

• What they are: Compact, portable units operated manually with a torch.
• Power range: Usually 30–80 amps, cutting up to 25mm (1″) thickness.
• Best for: Workshops, small businesses, automotive repair, maintenance teams.
• Pros:
  • Affordable and widely available
  • Easy to set up and use
  • Portable for on-site work
• Cons:
  • Limited to operator skill — cuts can be less precise
  • Not ideal for complex, repeatable shapes

2. Mechanised Plasma Cutters

• What they are: Plasma torches mounted on a track or gantry system, providing automated, straight, or curved cuts.
• Power range: Typically 80–200 amps, capable of cutting thicker materials.
• Best for: Fabrication shops that need consistent, repeatable parts.
• Pros:
  • Increased consistency and cut quality
  • Faster than handheld cutting for production runs
  • Can be retrofitted to cutting tables or gantries
• Cons:
  • Requires more space than handheld units
  • Higher upfront investment

3. CNC Plasma Cutters

• What they are: Computer Numerical Control (CNC) machines that automate plasma cutting with programmed designs.
• Power range: Can exceed 200 amps; some industrial systems cut over 160mm (6 1/4″) thick.
• Best for: Industrial fabrication, shipbuilding, aerospace, and large manufacturing.
• Pros:
  • High precision and repeatability
  • Ability to cut intricate shapes and patterns from CAD files
  • Reduces labour costs and material waste
• Cons:
  • Significant capital investment
  • Requires operator training and CAD/CAM knowledge
  • Larger footprint in workshops

4. Mini & Portable Plasma Cutters

• What they are: Lightweight, inverter-based machines designed for portability.
• Power range: Usually 20–40 amps, suited for thin sheet metal.
• Best for: DIY users, light fabrication, on-site maintenance.
• Pros:
  • Very portable, some weigh under 10kg
  • Affordable entry point for plasma cutting
  • Runs on standard power supplies (110/240V)
• Cons:
  • Limited cutting capacity (generally up to 6–10mm)
  • Not designed for heavy-duty or industrial use

5. Specialty Plasma Cutters

Beyond standard plasma cutters, there are advanced plasma cutting machines. Designed for specific applications and high-precision work. These systems are typically found in fabrication shops, shipyards, and industrial manufacturing.

• Plasma Tube and Pipe Cutters
  • What they are: Machines purpose-built for cutting round, square, or rectangular tubing and pipe.
  • Applications: Widely used in construction, oil & gas, shipbuilding, and fabrication. Where pipelines or structural frames need accurate joins.
  • Benefits:
    • Cuts complex angles, saddle joints, and hole patterns directly into pipes.
    • Improves fit-up accuracy for welding and reduces material waste.
• CNC Plasma Cutters with Bevelling Capabilities
  • What they are: CNC plasma systems equipped with a bevelling head. Allowing tilting and rotating of the torch to cut edges at precise angles.
  • Applications: Perfect for preparing weld edges on heavy plate and structural steel. As well as shipbuilding components.
  • Benefits:
    • Automates bevel cuts (V, X, Y, K profiles) that would otherwise need secondary machining.
    • Saves time and increases accuracy in weld preparation.
• High-Definition Plasma (HD Plasma)
  • Delivers laser-like cut quality with tighter tolerances.
  • Reduces dross and provides smoother edges for industries like aerospace and automotive.
• Dual-Gas Systems
  • Allow operators to optimise gas mixes for specific metals (e.g., oxygen for carbon steel, nitrogen for aluminium).
  • Improves cut quality and consumable life.
  • Systems with both plasma and oxy-fuel cutting offer maximum versatility for various materials and thicknesses.
• Plasma Gouging Systems
  • Adapted to remove welds, faulty joints, or surface defects without fully cutting through material.
  • Common in repair, maintenance, and rework operations.

Which Type Should You Choose?

• Hobbyist or light user? A portable handheld unit is usually sufficient.
• Small workshop or garage? Step up to a handheld mid-range unit for cutting up to 20mm steel.
• Fabrication shop or manufacturer? Mechanised or CNC plasma systems provide speed, accuracy, and consistency.
• High-precision industries? HD plasma offers laser-like quality without the cost of a laser cutter.

Read our buying guide in the next section to learn more!

How to Choose the Right Plasma Cutter

With so many models available, selecting the right plasma cutter can feel overwhelming. The best choice depends on what you’re cutting, how often you’ll use the machine, and the type of finish you need.

Here’s a structured approach to help narrow it down.

Step 1: Identify Your Materials

• Type of Metal: Mild steel, stainless steel, aluminium, copper, or mixed use?
• Thickness Range: Consider both your most common thickness and the maximum you’ll need to cut.
• Finish Requirements: Do you need a rough cut that will be welded later? Or clean edges ready for assembly?

Step 2: Match Cutting Capacity to Machine Power

• Light-duty units (30–40A): Up to 10mm (13/32″) clean cuts. Great for sheet metal and small jobs.
• Medium power (40–80A): 10 – 32mm (13/32″ – 1 1/4″). Suited for workshops, garages, and fabricators.
• Heavy-duty (80–200A): 25 – 50mm (1 – 2″). Designed for industrial cutting.
• CNC/industrial systems (>200A): 50mm+ (2″+). For thick plate, production, and automation.

Tip from Craig: Always check the recommended clean cut thickness. Not just the maximum severance thickness advertised.

Step 3: Consider Your Power Supply

• Single-phase (110/240V): Works for small/portable machines, ideal for garages and mobile users.
• Three-phase (400V): Required for higher-powered plasma systems and CNC machines.
• Inverter technology: Offers better efficiency and lighter machines compared to older transformer units.

Step 4: Think About Duty Cycle

The duty cycle shows how long the machine can cut within a 10-minute period before it needs to cool.

• Hobby/light work: A 35–40% duty cycle may be enough.
• Industrial/production use: Look for 60–100% duty cycles to avoid downtime.

Step 5: Choose Between Portability and Productivity

• Portable Handheld Units: Lightweight, often under 15kg, ideal for site work.
• Bench-mounted/Mechanised: Heavier but more stable for repeated use.
• CNC Systems: Fixed installations offering automation and high productivity.

Step 6: Factor in Consumables and Operating Costs

• Electrodes, nozzles, and swirl rings wear over time.
• Higher-end machines may offer longer consumable life, reducing downtime and overall cost.
• Air supply or gas requirements also add to ongoing expenses.
• Inverter powered systems offer a more energy-efficient solution.

Step 7: Match the Machine to Your Application

• Automotive repair: Portable handheld unit, 30–50A.
• Fabrication shop: Medium–heavy duty handheld or mechanised machine.
• Industrial production: CNC plasma with automation, bevelling, or pipe-cutting capability.
• High-precision work: High-definition (HD) plasma or hybrid systems.

Step 8: Balance Budget vs. Long-Term Value

• Entry-level machines start under £1,000, but may have limitations in duty cycle and consumable life.
• Industrial CNC systems cost more initially, but can save money through speed, accuracy, and reduced rework.
• A used or refurbished unit can be a cost-effective entry point. Especially from a trusted supplier like us, where every machine is tested and backed by expert support. Supplied with warranties as standard.

Key Buying Checklist

• ✅ Material type and thickness you’ll cut most often
• ✅ Clean cut vs maximum cut requirements
• ✅ Power supply available (single- or three-phase)
• ✅ Duty cycle and intended frequency of use
• ✅ Portability vs fixed installation
• ✅ Consumable costs and gas/air supply
• ✅ Budget and long-term operating costs

Setup & Operation Basics

Correct setup is essential for safe, efficient plasma cutting. While every machine has its own specifications, the principles are largely the same.

Here’s a step-by-step overview to help you get started.

1. Prepare the Work Area

• Ensure the workspace is clean, dry, and well-ventilated.
• Remove any flammable materials from the area.
• Position your workpiece securely on a stable, grounded metal table or stand.

2. Connect Power & Air/Gas Supply

• Power: Match your plasma cutter to the available supply (single-phase 110/240V or three-phase 400V).
• Air/Gas: Connect a clean, dry compressed air supply (most machines require ~4–6 CFM at 90–120 PSI).
  • Some industrial systems use gases like nitrogen or oxygen for improved cut quality on certain materials.
• Moisture filters or air dryers can help extend consumable life and improve cut consistency.

3. Attach Ground Clamp

• Secure the ground clamp to the workpiece or cutting table.
• A solid electrical connection is essential for a stable arc and consistent cuts.

4. Torch Setup & Consumables

• Check the electrode, nozzle, and swirl ring for wear and replace if necessary.
• Assemble the torch according to manufacturer instructions, ensuring consumables are properly in place.
• Fit the correct nozzle size for your intended cut (thickness and amperage).

5. Pre-Cut Settings

• Amperage: Set according to material thickness (higher amps = thicker cuts).
• Air pressure: Adjust to recommended PSI for clean cuts without excessive dross.
• Standoff distance: Maintain the correct gap between nozzle and workpiece (often 1–3mm for handheld cutting).
  • Many torches use a drag shield or standoff guide to help maintain consistent distance.

Please refer to your specific machine’s operating manual for the above details.

6. Cutting Technique

• Hold the torch perpendicular to the workpiece for straight cuts, or angle slightly for bevel cuts.
• Begin at the edge of the material or pierce through by holding the torch steady until the arc passes fully through.
• Move smoothly and steadily along your cut line. Too slow can cause dross build-up, too fast may leave incomplete cuts.
• For curves or patterns, practice steady wrist movements or use a cutting guide.

7. Post-Cut Procedure

• Release the trigger to stop the arc, then allow the post-flow of gas to cool the torch.
• Inspect the cut edge for dross (molten metal that sticks to the underside). Light grinding may be needed for rougher cuts.
• Power down and disconnect air supply if the machine won’t be used again immediately.

Pre-Cut Checklist

✅ Clear workspace and remove flammables

✅ Connect power and air supply

✅ Attach ground clamp securely

✅ Inspect and install fresh consumables

✅ Set correct amperage and air pressure

✅ Wear full PPE (gloves, helmet, flame-resistant clothing, eye/ear protection)

Plasma Cutting Safety Essentials

Plasma cutting is a safe and reliable process when carried out correctly.
However there are risks involved. Including high temperatures, bright arcs, molten metal, and pressurised gases.
Following best practices not only protects operators but extends the life of your equipment.

1. Personal Protective Equipment (PPE)

• Eye Protection:
  • Use a welding helmet or plasma-specific shield with the correct shade lens. This is usually shade 5–9 depending on amperage.
  • Plasma arcs produce intense UV and infrared radiation that can cause arc eye (a painful eye burn) without proper protection.
• Protective Clothing:
  • Wear flame-resistant clothing (cotton or FR-rated workwear). Avoid synthetics, which can melt onto skin.
  • Use welding gloves rated for heat resistance and dexterity.
  • Safety boots with steel toecaps protect against falling material and sparks.
• Hearing Protection:
  • Plasma cutting can exceed 85 dB, especially with high-power machines. Ear protection is recommended, particularly in production workshops.

2. Ventilation & Fume Extraction

• Plasma cutting produces fumes and gases that can be harmful in enclosed spaces.
• Always work in a well-ventilated area and use a fume extraction system suitable for the machine type.
• When cutting materials with coatings (paint, galvanised steel), fumes can be especially hazardous. In this instance, respiratory protection is always necessary.

3. Fire Safety

• Keep a fire extinguisher rated for electrical/metal fires within reach.
• Clear the area of flammable materials (solvents, rags, wood, paper).
• Sparks can travel several metres, so set up protective screens if needed.

4. Safe Operation Practices

• Check consumables regularly. Worn nozzles or electrodes can cause unstable arcs, increasing safety risks.
• Grounding. Ensure the ground clamp is firmly connected before cutting. Poor grounding can damage the torch and create unstable arcs.
• Cable and hose care. Avoid tripping hazards and keep cables away from hot metal.
• Dry environment. Never operate a plasma cutter in wet conditions. Moisture can increase the risk of electric shock.

5. Training & Awareness

• Operators should be trained in both machine setup and emergency procedures.
• Beginners should practice on scrap metal before attempting precision work.
• Always follow the manufacturer’s operating manual for machine-specific safety requirements.

Safety Checklist

✅ Wear full PPE: helmet, gloves, FR clothing, boots, ear protection

✅ Ensure good ventilation or fume extraction

✅ Remove flammable materials and keep a fire extinguisher nearby

✅ Inspect consumables, cables, and hoses before cutting

✅ Never cut in wet or damp conditions

✅ Follow manufacturer’s guidelines and safe working practices

Maintenance & Consumables

Plasma cutters are rugged machines. But like any tool, they perform best when maintained properly. Regular upkeep not only improves cut quality, but also extends the lifespan of both the machine and consumables.

Why Consumables Matter

Inside the torch, consumables shape and control the plasma arc. These parts degrade over time due to the extreme heat and pressure involved in cutting.

Running with worn consumables reduces cut quality and increases dross. It can even cause damage the torch body.

Main consumables include:

• Electrode: Conducts electricity to form the arc.
• Nozzle (Tip): Shapes and constricts the plasma jet for accuracy.
• Swirl Ring: Directs airflow to stabilise the arc.
• Shield/Drag Cap: Protects the nozzle and helps maintain standoff distance.

Signs Consumables Need Replacing

• Poor cut quality (wider kerf, rough edges, excessive dross).
• Difficulty starting the arc or unstable arc during cutting.
• Visible wear: pitting, burn marks, or out-of-round nozzle holes.
• Increased gas consumption due to leaks or worn seals.

Extending Consumable Life

• Always use clean, dry air or gas. Moisture or oil contamination shortens consumable lifespan.
• Operate at the correct amperage for nozzle size. Overpowering can quickly damage nozzles.
• Maintain the correct standoff distance to prevent nozzle blowback.
• Use a steady cutting speed. Moving too slowly overheats consumables.
• Inspect and replace consumables as a set where possible (electrode + nozzle). This maintains wear time consistency.

General Machine Maintenance

• Inspect cables and hoses: Check for cracks, leaks, or damage before each use.
• Keep the torch clean: Remove metal dust, spatter, or debris regularly.
• Air filters/dryers: Replace filters as recommended to protect internal components.
• Cooling systems (if water-cooled): Check coolant levels and quality.
• Storage: Store machines in a dry, dust-free environment. Preventing corrosion or electrical issues.

Maintenance Schedule (Typical)

• Daily: Check consumables, torch, cables, and airflow.
• Weekly: Inspect filters, drains, and coolant levels.
• Monthly: Clean torch body, check for loose connections, inspect air supply.
• As needed: Replace consumables at first signs of wear — don’t wait for failure.

Why Maintenance Matters

• Improved cut quality: Consistent, smooth edges with less secondary finishing.
• Lower operating costs: Longer consumable life means fewer replacements.
• Reduced downtime: Prevents unexpected machine failure.
• Safety: Well-maintained machines are safer to operate. Leading to fewer arc instabilities or overheating risks.

Plasma vs Other Cutting Methods

Plasma cutters are faster and more versatile than oxy-fuel and mechanical cutting. Working on all conductive metals including aluminium and stainless steel. Compared to laser cutting, plasma is more affordable and better for medium-to-thick plate. While laser excels at ultra-precise cuts on thin sheet metal.

Here’s a more detailed comparison:

Plasma Cutting vs Oxy-Fuel Cutting

• Process: Oxy-fuel uses a flame and oxygen jet to oxidise and blow away molten steel.
• Limitations: Only works effectively on ferrous metals (steel and iron).
• Plasma Advantage: Cuts a wider range of metals. Including stainless steel, aluminium, copper, and brass. It’s also faster and cleaner on thin-to-medium materials.
• When to Choose Oxy-Fuel: For very thick carbon steel (>150mm / 6″) where plasma or laser isn’t practical.

Plasma Cutting vs Laser Cutting

• Process: Laser uses a highly focused beam of light to melt and vaporise metal.
• Limitations: High upfront cost, slower on thick plate, often requires specialist gases.
• Plasma Advantage: More affordable, faster on medium-to-thick materials, portable options available.
• When to Choose Laser: For ultra-precise, fine-detail cutting of thin metals. E.g. electronics, decorative work, aerospace.

Plasma Cutting vs Mechanical Methods (Sawing/Grinding/Shearing)

• Process: Mechanical cutting uses physical force to remove or separate material.
• Limitations: Slower, more labour-intensive, higher wear on blades.
• Plasma Advantage: Faster, cleaner cuts with less manual effort. As well as the ability to handle complex shapes.
• When to Choose Mechanical: Where sparks and heat must be avoided. Or in very low-budget settings.

Where Plasma Stands Out

• Versatility: Cuts nearly all conductive metals.
• Speed: Particularly efficient on thin-to-medium sheet and plate.
• Accessibility: Portable handheld units make it viable for workshops and mobile use.
• Cost-effectiveness: Less expensive than lasers and more flexible than oxy-fuel.

Common FAQs About Plasma Cutters

What is a plasma cutter?

A plasma cutter is a machine that uses electricity and compressed gas to create a superheated plasma jet. This jet melts and blows away metal, allowing fast, precise cuts on conductive materials like steel, aluminium, and copper.

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How does a plasma cutter work?

The cutter creates an electrical arc between an electrode in the torch and the workpiece. Compressed gas is forced through a nozzle, where the arc superheats it into plasma. The plasma jet melts the metal, while the high-pressure gas clears away molten material to form a cut.

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What metals can a plasma cutter cut?

Plasma cutters can cut all electrically conductive metals, including:

• Mild steel
• Stainless steel
• Aluminium
• Brass
• Copper
  Some advanced plasma systems can also handle exotic alloys like titanium and Inconel.

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How thick can a plasma cutter cut?

• Light-duty machines (30–40A): Up to 6mm (¼”) clean cuts
• Medium machines (40–80A): Up to 20mm (¾”) clean cuts
• Heavy-duty (80–200A): Up to 40mm (1½”) clean cuts
• CNC/industrial plasma: Up to 150mm (6″) with specialised systems

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Is plasma cutting safe?

Yes, when used with proper safety equipment and practices. Operators should wear welding helmets or shields, gloves, flame-resistant clothing, and hearing protection. Ventilation or fume extraction is essential to control fumes, and the workspace should be cleared of flammables.

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What is the difference between a handheld and a CNC plasma cutter?

• Handheld plasma cutters are portable, easy to use, and best for light-to-medium cutting jobs.
• CNC plasma cutters are automated systems that use programmed designs to cut with precision and repeatability, ideal for industrial production.

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How much does a plasma cutter cost?

Prices vary widely:

• Entry-level handheld units: under £1,000
• Mid-range workshop machines: £2,000–£5,000
• CNC plasma tables and high-definition systems: £10,000–£100,000+
  Buying refurbished equipment can significantly reduce upfront costs while still delivering reliable performance.

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What are plasma cutter consumables?

Consumables are the wear parts inside the torch, including the electrode, nozzle, swirl ring, and shield. They control the plasma arc and need regular replacement. Good airflow and correct machine settings extend their lifespan.

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Plasma vs laser cutting: which is better?

• Plasma: Faster and more cost-effective for medium-to-thick metals, versatile across materials.
• Laser: Superior precision and edge quality on thin metals, but with higher upfront and operating costs.

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Can plasma cutters be used for pipe or tube cutting?

Yes. Specialist plasma tube and pipe cutting systems can cut angles, saddles, and holes into cylindrical material, making them invaluable in industries like construction, shipbuilding, and oil & gas.

What Gas is Needed for a Plasma Cutter?

Many fabricators choose plasma systems with “dual-gas” or “multi-gas” capability. This means that a variety of plasma and shield gases can be used for various applications. Multi-gas torches offer the most flexibility for shops that cut a variety of materials. Different gases are used, depending on material type and thickness, in order to achieve the best balance of cut quality, parts life, productivity, and overall cost of operation. Most plasma system manuals tend to overwhelm the operator with a confusing array of cut charts and gas choices. 

What Can a Plasma Cutter Cut Through?

A plasma cutter can cut through electrically conductive materials. 

The three most common materials are mild steel, stainless steel and aluminum but it can cut through copper, brass and any other conductive metal.    

Can I Cut Cast Iron with a Plasma Cutter?

Plasma works well on most anything that conducts electricity and can certainly cut through cast iron along with steel, copper and other conductive metal.

Can I Cut Aluminium with a Plasma Cutter?

It cuts aluminum great. It’s just that raw plasma-cut edges aren’t ideal for welding because of the oxides. You would also have to choose your gas carefully.

Can You Use a Plasma Cutter on Aluminium?

If you want to cut aluminium with a plasma cutter make sure you use nitrogen or a mix with oxygen as this will improve the cut quality and extended the life of your parts. With the proper selection of gases, you can get a very nice edge on aluminum with plasma.  The main issue is oxidization but advances in technology mean that a plasma cutter will definitely cut aluminium but it is worth seeking advice to fine tune the process.  

Can You Weld with a Plasma Cutter?

There are some multi-function plasma cutters that you can also MMA and TIG weld with. Often called a 3in1. They are not favoured by the professional workshop and should only be consider if using very occasionally. It is much better to buy separate systems.

How Thick Can You Cut with a Plasma Cutter?

Once you start to get into the nitty gritty of a plasma cutter’s features, maximum cut thickness is going to be the first specification that you’ll want to check. It refers to the ideal upper limit on metal thickness that you can cut comfortably while still achieving smooth lines. The maximum thickness a plasma cutter can cut is 150mm. You would probably use a cnc plasma cutting table with mechanised torches to cut 6in thick heavy steel plate.

How Hot is a Plasma Cutter?

The temperature of the plasma is in excess of 20 000°C and the velocity can approach the speed of sound. When used for cutting, the plasma gas flow is increased so that the deeply penetrating plasma jet cuts through the material and molten material is removed in the efflux plasma.

How Hot is a Plasma Cutting Flame?

Hot enough to make your fingers vanish. The intense heat of a plasma cutter can reach 20,000 degrees Celsius that is a massive 45, 000 Fahrenheit.  With the velocity which can approach the speed of sound this is potentially a dangerous machine.

How Long Do Plasma Cutter Tips Last?

It’s hard to be specific about exactly when you’ll need to replace your nozzle and electrode, as this will depend on many factors, including the speed you cut, the thickness of the workpiece and the amount of amperage you use. However, it is a good idea to replace your nozzle and electrode at the same time (according to whichever wears out first), as this will put you back to optimum cutting performance, rather than using a new electrode with a worn and inconsistent nozzle.

Can You Get Flash Burn from a Plasma Cutter?

A plasma cutting arc, like any electric arc, gives off a broad spectrum of electromagnetic radiation, which extends all the way from Infrared light (IR), through the visible spectrum, and into the Ultra Violet (UV) range. Plasma cutting arcs can also be very intense, because the arc current is typically anywhere from 100 to 800 Amperes. Needless to say, looking at an arc that intense can easily cause eye damage, including permanent damage leading to blindness.

How Does a CNC Plasma Cutter Work?

A CNC plasma cutting system is a machine that carries a plasma torch, and can move that torch in a path directed by a computer. The term CNC refers to Computer Numerical Control which means that a computer is used to direct the machines motion based on numerical codes in a program. A CNC plasma cutter is necessary to achieve accurate and edge quality cuts for most metal fabrication projects.  

A mechanised plasma torch is normally straight and carried by the profile cutting table compared to that of a hand held torch. CNC plasma cutting involves cutting through electrically conductive materials by utilizing an accelerated jet of hot plasma that is directed right at the material being cut; steel, aluminum, brass, and copper. 

CNC plasma cutters vary widely in size, price, and functionality. The machines are highly accurate and fast cutting through, slicing metals at speeds of up to 500 inches per minute. Plasma cutters require a plasma gas and an assist gas to function, and they vary according to the material being cut.

Unlike many hobby CNC systems, a plasma cutter needs a large amount of space in a well-ventilated area in order to operate it safely.

Westermans have nearly 60 years’ experience providing quality new and used plasma cutters for sale in the UK and internationally. We offer new, used and refurbished Plasma cutting systems, plasma profile cutters and CNC plate cutters in stock. For more information, or to answer any questions you might have, get in touch with our team today.