Every cutting process has particular benefits and shortcomings that you should take into account before deciding on a cutting method. Also keep in mind that a combination of processes may be best for a particular application.
| Cutting process | Waterjet | Laser | Plasma | Oxyfuel | Other mechanical tools (saw, shears, etc.) | |
|---|---|---|---|---|---|---|
| Conventional plasma | X-Definition™ (X) / High performance plasma (HD) | |||||
| Materials | Range of materials | Metal, wood, plastics, foam, materials | Most electrically conductive metals | Most electrically conductive metals | Carbon steel | Metal, wood, plastic |
| Thickness | Range of thicknesses | Historically used on thinner materials but can cut up to 32 mm (1-1/4”) |
Up to 75 mm (3”) handheld Up to 32 mm (1-1/4”) mechanized pierce |
Up to 80 mm (3.2”) mild steel (HD and X) Up to 160 mm (6.25”) stainless steel (HD) Up to 75 mm (3") stainless steel (X) |
Range of thicknesses | Typically up to 25 mm (1”) |
| Cut quality | Excellent quality with high tolerances | Excellent quality with high tolerances | Good quality, may require some secondary operations |
Extremely good quality, virtually dross free, good fine feature capability New processes optimize non-ferrous cutting |
Ranges from poor to very good quality depending on the operator’s skill | Very good quality if operator is skilled and using low cutting speeds |
| Productivity | Low to high, depending on material | High productivity on thinner materials | Medium | Medium to high, depending on material thickness | Low, though can be improved by running multiple torches simultaneously | Low |
| Speed | Low to high, depending on material | High cut speeds for thinner materials, low cut speeds for thicker material | Medium | High cut speeds | Slow cut speeds, multiple torches can help increase productivity | Slow cut speeds |
| Secondary operations | Grinding sometimes needed | Occasional dross removal needed | Grinding and surface oxidation removal almost always needed | Filing or grinding almost always needed | ||
| Operating cost | $$$ |
$$$ (Higher cost for CO2 lasers) |
$ |
Less than a third of $ (X) $ (HD) |
$$ | $$$$ |
| Capital equipment cost | $$$ | $$$$ | $ | $$$ | $ | $ - $$$$ |
| Portable | No | No | Yes (air plasma systems only) | No | Yes | Yes |
| Heat affected zone | None | Yes | Yes | Yes | Yes | Possibly |