Plasma cutters are now widely used in industrial sites, small craft shops, etc. Earlier, these sectors were solely dependent on Oxy-Fuel for cutting different materials. Cutting requirements and how many types of plasma cutters vary based on the individuals and businesses. So, it is important to know which plasma cutters to begin with?
Plasma cutter types depend on the intended use of a person. Portability, usability, and productivity are some variables that need to be considered when buying a plasma cutter. Moreover, plasma cutters are a great option for many projects for their low cost, precision, and speed.
Continue reading this comprehensive guide to learn more about plasma cutter types, uses, and other important factors.
What Is Plasma Cutting?
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In order to cut electrically conductive materials like copper, brass, stainless steel, steel, aluminum, etc. accelerated jet of hot plasma is required. In plasma cutting, this hot plasma gets generated and easily cuts electrically conductive materials.
Before buying a plasma cutter, a user should learn how it works and how to use it to get the most out of it.
How Does Plasma Cutter Work?
We all know that every matter has 3 states: gas, liquid and solid. Plasma is the other state of matter found when the steam and heat are combined, and gas becomes ionized and electrically conductive.
Electrically conductive gas plays a significant role in plasma cutting as plasma cutters work, taking assistance from it. Moreover, the energy gets transferred from a power supply to a conductive material due to gas like oxygen, argon, or nitrogen. A plasma cutter works when the gas is forced inside the torch with a small nozzle hole.
The external power supply generates an electric arc introduced to the high-pressure gas flow creating a plasma jet. The temperature of the plasma jet can be a maximum of 40° F. As a result; the plasma cutter can easily cut different materials.
How Many Types of Plasma Cutter?
You will find different plasma cutters in the market. They come with distinctive features and benefits. Here we will be looking at the types of plasma cutters. Read carefully.
| Factors | Automatic Plasma Cutter | CNC Plasma Cutter | Manual Plasma Cutter | Inverter Plasma Cutter | Transformer Plasma Cutter |
| Subcategories | N/A | 2 Dimensional, 3 Dimensional, Tube and Section | Conventional and HD Precision | N/A | N/A |
| Uses | Heavy-duty steel cutting projects | Versatile and can cut thicker materials | Small to medium cutting projects | Light cutting tasks | Heavy-duty tasks |
| Suitable for | Industrial sites | Industrial and commercial sites | Auto repair shops, homes, garages, etc. | Auto repair shops, homes, garages, etc. | Industrial sites |
Let’s look at the in-depth discussion on the types of plasma cutters
Automatic Plasma Cutter
If you need to tackle large-scale cutting tasks, buy an automatic plasma cutter. These are big units and are largely used in industrial sites for heavy-duty steel cutting projects. These cutters are computer-operated, and the control head is mounted on the table.
When buying automatic plasma cutters, consider the below factors carefully,
- Highest size of the cutting material
- Maximum thickness of the material
- Total sheet quantity when cutting
- Measurement of your working space
- Required tool or consumables when dealing with automatic plasma cutters
Since it is computer-operated, it would be best to hire someone capable of creating and editing the CAD files that automatic plasma cutters import.
CNC Plasma Cutter
The full form of CNC is Computer Numerically Controlled, which means it is also a computer-operated plasma cutter.
CNC plasma cutters offer numerous automated options. A wide range of parameters and variables are available since machine types are several. So, choose carefully when it comes to buying a CNC plasma cutter.
There are 3 main types of CNC plasma cutters available in the market. Differences between these types are also quite significant.
2 Dimensional: It is widely used among the other 2 types and creates clean results by cutting the edges at a 90° angle to the surface of the materials. These machines can cut metals a maximum of 150mm thick.
3 Dimensional: You will get clean cuts from these CNC plasma cutters also, but rather than delivering a 90° angle cut, it rotates the 3rd axis, allowing to cut edges that are not 90°. As it can cut metal following different angles, 3D/3+ axis CNC plasma cutters are suitable for making chamfer edges and countersunk holes of profiled holes.
These CNC plasma cutters are highly versatile, making them the best option for cutting profiles. Since you can make 30° or 45° cuts, welding 2 metal pieces becomes easier. More importantly, machining or grinding is unnecessary when welding. This way, the cost is saved.
Tube and Section: A tube and section CNC plasma cutter is beneficial when processing piping, tubing, and other long material sections. Generally, its cutting head is stationary; according to its configuration, the cutting head can be tilted or rotated. Due to this movement, cutting of different angles becomes effortless.
Manual Plasma Cutters
Handheld plasma cutters are known as manual systems, delivering high-cutting amperage. Manual plasma cutters are ideal for small to medium cutting or trimming small metal pieces. These units are commonly found in auto repair shops, garages, homes, etc. These plasma cutters are 2 types.
Conventional Plasma Cutter: These devices don’t use plasma gas for cutting. Instead, they use shop air. The nozzle tip determines the arc shape, and the amperage range is 12 – 20 k Amps/sq. inch.
HD Precision Plasma Cutter: Are you looking to make an HD precision-cut? Choose an HD precision plasma cutter without hesitation. This cutter uses compressed air, nitrogen, oxygen, and argon/nitrogen/hydrogen mixture. The amperage range of HD precision plasma cutters is 40 – 50 k Amps/sq. inch.
Inverter Plasma Cutter
This type of plasma cutter uses a high mains-frequency transformer of more than 2 KW voltage. The inverter corrects the main supply to the plasma cutter DC. Here, the high-frequency transistor inverter range is 10 kHz – 200 kHz. Due to the high frequency, a plasma cutter uses a smaller transformer. As a result, the plasma cutter becomes lightweight and highly portable.
Transformer Plasma Cutter
This plasma cutter utilizes rectifiers for converting AC current to DC current. They are highly durable and come with average cutting quality. You need to be skilled and experienced in operating a transformer plasma cutter. Their duty cycle is pretty low, roughly 25% – 35%, so frequent breaks are necessary while working with them. Another important thing is that they are quite bulky. This way, carrying them to different places is quite challenging. These plasma cutters are the ideal choice for industrial sites.
What to Consider When Buying a Plasma Cutter?
It is important to remember that plasma cutters are different based on industrial and home use. Valuable time, money, and effort will be wasted if you don’t know what to consider when buying a plasma cutter.
Usability, Productivity, and Portability
Compact plasma cutters are incredibly transportable. Thus, a welder or contractor can easily carry the plasma cutters to their job site.
The wide range of usability of plasma cutters is simply satisfying. In most industries, they are quite a handy tool and offer benefits in different other areas of productivity.
Tips to Follow When Operating a Plasma Cutter
Skill is essential when plasma cutting; simultaneously, you need to follow a few tips in order to get the required clean cuts.
- Stability is mandatory during plasma cutting. For this, hold your served hand with a non-served hand.
- “Practice makes a man perfect.” Before cutting, practice a couple of times to trace the pattern. This will help you gain the flow within a short time.
- Grab a small piece of metal, and do a test cut to set the plasma cutter at the right speed and amperage.
- You can effortlessly cut straight edges with the help of roller guides.
- Cutting various sizes of perfect circles will be easier with circle guides.
What Safety Requirements to Follow When Working with Different Types of Plasma Cutter?
Without wearing safety gear, you mustn’t attempt to work with a plasma cutter. Although plasma cutters are handy machines, serious injury can happen if not handled properly.
Here are a few safety requirements when working with a plasma cutter.
- Wear a welding helmet to protect your eyes and face
- Welding jacket will prevent sparks, protecting your arms and torso
- Wear utility jeans to keep your legs safe from sparks
- Keep a fire extinguisher within hand reach
Frequently Asked Question
What gas is best for a plasma cutter?
Plasma cutters require gas to work and create the plasma. Different gases are used in a plasma cutter, and each gas is suitable for specific materials.
| Gas Type | Suitable for | Reason |
| Oxygen | Steel | Fastest cutting speed |
| Nitrogen | Stainless steel and aluminum | Excellent cut quality |
| Argon | Thick aluminum and stainless steel | Hottest burning plasma |
| Dry shop air | Mild steel, stainless steel, aluminum | Economical choice |
Can a plasma cutter cut painted metal?
Yes, a plasma cutter can cut painted metal. In this case, a clean metal piece requires a stable connection.
However, a plasma cutter will face difficulty cutting through painted metal if the metal piece is moisturized or wet. Moreover, the machine can blow out if there is too much air.
So, make sure the painted metal is not wet and moisturized to avoid problems while cutting with a plasma cutter.
What metals can a plasma cutter cut?
Plasma cutters can cut only conductive materials. The metals are,
- Aluminum
- Mild steel
- Monel
- Cast iron
- Stainless steel
- Brass
- Copper
- Inconel
- Titanium
Some of these metal melting points are high, making it difficult to work with them. If a metal’s electrical conductivity increases, the cutting capacity of the plasma cutter decreases, resulting in a pool and unclean cut.
Final Words
Hopefully, the types of plasma cutter will help you find the required plasma cutter for your project. Buying the best-quality and right machine is significantly important because the result and long-term service depend greatly on machine quality.
Make sure to invest your valuable time, money, and effort in the right plasma cutter. Always choose a plasma cutter type that meets your project requirement. When working with a plasma cutter, a wrongly chosen product will ruin your efficiency and productivity.