Technical Foundation
What Is a Plasma Cutter?
A plasma cutter uses an electrical arc passed through a compressed gas (typically shop air) to ionize it into plasma, a superheated, electrically conductive gas jet that melts through conductive metal and blows the molten material away, producing a fast, narrow-kerf cut. Because the process relies on electrical conductivity through the workpiece, plasma cutting works on steel, stainless, aluminum and other conductive metals but cannot cut non-conductive materials like wood or plastic.
Output amperage is the primary rating that determines cut capacity: higher amperage cuts thicker material and cuts faster through a given thickness, with manufacturers publishing both a rated 'clean cut' thickness (production-quality edge) and a slower 'severance cut' maximum (cuts through, but rougher edge, mainly for demolition work). CNC plasma systems add a pilot-arc torch (which can start cutting without touching the workpiece, important for cutting expanded metal or painted/rusty surfaces) and interface with motion control software for shape-cutting programs.
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| Spec | What It Means | Why It Matters |
|---|---|---|
| Output Amperage | Handheld: 30-90A; industrial/CNC: 100A+ | Amperage directly sets clean-cut thickness capacity and cutting speed |
| Clean Cut vs. Severance Rating | Clean cut = production quality; severance = max cuttable thickness | Severance cut sacrifices edge quality and speed — not suited to production work |
| Input Power | 120V, 240V single-phase; 208-575V three-phase (industrial) | Available shop power determines which unit can even be plugged in and run at rated output |
| Duty Cycle | % of a 10-minute period the unit can run at rated output | Low duty cycle units overheat and cut out under sustained production cutting |
| Pilot Arc | Contact-start vs. non-contact (pilot arc) | Pilot arc allows cutting expanded metal, grates, and painted/rusty surfaces without direct torch contact |
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Applications
Where Plasma Cutters Get Used
Plasma cutters are specified by material thickness, available power, and whether the job needs handheld portability or CNC-programmed shape cutting.
Metal Fabrication Shops
Handheld and CNC plasma cutting for structural steel, plate, and sheet metal fabrication.
Automotive Repair & Restoration
Handheld plasma cutters for rust repair, panel removal, and exhaust system work.
Sign & Metal Art Fabrication
CNC plasma tables cutting precise decorative and structural shapes from steel and aluminum sheet.
Demolition & Salvage
Portable plasma cutters for cutting structural steel and salvage material on site.
Shipbuilding & Heavy Fabrication
High-amperage industrial plasma systems for cutting thick steel plate in production environments.
Maintenance & Field Repair
Portable dual-voltage plasma cutters carried by maintenance crews for on-site cutting of steel components.
FAQ
Plasma Cutters Questions, Answered
What amperage plasma cutter do I need for my material thickness?
As a rough guide, a 30-40A unit clean-cuts up to about 3/8", a 50-60A unit up to about 5/8"-3/4", and 80-90A+ handles up to roughly 1"-1.25" clean cut, with actual capacity varying by manufacturer and consumable condition. Always check the specific unit's published clean-cut rating rather than relying on amperage alone, since torch and consumable design affect real-world capacity.
What's the difference between clean cut and severance cut ratings?
Clean cut is the maximum thickness the unit cuts through at a production-quality edge and reasonable speed — the number to use for actual fabrication work. Severance cut is a higher, slower maximum thickness the unit can cut through at all, with a rougher edge, typically only useful for one-off demolition or salvage cuts, not repeatable production work.
Do I need three-phase power for a plasma cutter?
Smaller handheld units typically run on single-phase 120V or 240V power, making them usable in most shops and job sites, often with dual-voltage capability. Higher-amperage industrial and CNC systems (100A+) generally require three-phase power to deliver the sustained output needed at higher duty cycles — check the unit's input power requirement against your shop's actual electrical service before purchasing.
What is duty cycle and why does it matter?
Duty cycle is the percentage of a 10-minute period a unit can run continuously at its rated output before it needs to cool down — a 60% duty cycle at 60A means 6 minutes of cutting followed by 4 minutes of rest. Production environments cutting for extended periods need a higher duty cycle rating than occasional hobbyist or repair use, or the unit will thermally shut down mid-job.
What consumables does a plasma torch need and how often do they wear?
Plasma torches use a consumable electrode, nozzle (tip), swirl ring, and shield cup that wear from the arc's heat and must be replaced periodically — wear rate depends on cutting amperage, material, pierce frequency and cut quality demands. Production shops typically keep consumable kits on hand rather than ordering individual parts as they wear.
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