Plasma cutting vs. laser cutting

Plasma can produce excellent cut quality.
The cut quality difference between X-Definition^® plasma technology, like that found on the XPR170^® and XPR300^®, and laser is very small. To compare the two technologies we reference ISO 9013, an agreed upon international standard for classifying the quality of parts cut with any thermal process. This classification says that cut quality, a measurement of a cut edge’s deviation from perpendicular, ranges from a range of 1 (the least amount of deviation) to 5 (the most deviation.)

When coupled with a cutting machine with superior motion capabilities, X-Definition plasma can deliver ISO Range 2 cuts on thin material, defined as thickness less than 10 mm (3/8″) and Range 3 cut quality on material on thicker material.

ISO range

In addition, X-Definition plasma can deliver edge surface finish that is generally smoother than fiber laser in the thicker ranges and extremely consistent edge quality over the full life of a consumable set. Combined, this allows X-Definition plasma to achieve cut quality that rivals laser This improved cut quality is true among various material types including mild steel, stainless steel, and aluminum.

Plasma costs less.
Consistent results across the life of the consumables deliver low part to part variability over a range of metal types and thicknesses, reducing scrap and finished part costs. In addition, plasma systems cost much less than laser. If you only cut a small amount of thin metal, you are unlikely to get the return needed to pay for your laser investment.

Plasma is fast.
Plasma is faster by far when cutting a wide range of material thicknesses. As the chart below demonstrates, plasma is faster when cutting all but the very thinnest sheet metal.

Cut speed per minute on mild steel

Understanding tolerances
Though laser is renowned for its tight tolerances, the difference between plasma and laser tolerances is smaller than one might think at roughly 0.25 mm (0.01″), or about the width of a business card. In addition, as this article on laser tolerances explains, added tolerances often come with cost tradeoffs.

Plasma can reduce labor costs and bottlenecks
When paired with CAD/CAM software like Hypertherm’s ProNest^®, it is possible to dramatically reduce labor costs and reduce downstream bottlenecks. Technology such as Hypertherm’s SureCut™ includes embedded process parameters that reduce complex programming, trial and error, and operator intervention. Here’s an example of how three SureCut processes can save time.

• True Hole^®. Produces more detailed and defined holes with much less taper and minimal lead-in and lead-out marks. In essence, True Hole makes it possible to create bolt-ready holes right on the plasma table which eliminates the need to drill holes in a separate step.
• True Bevel™. Automatically applies the correct cutting parameters so operators can cut beveled edges in one pass without the need for a second step, as is common with laser. Welders no longer have to manually cut or grind beveled edges to a specified angle.
• Rapid Part™. Targets and optimizes process steps considered non-value added. This includes the time needed for the plasma torch to retract and move into place, and steps like gas pre-flow. By shortening or eliminating non-cutting time, operators can cut more parts—in some cases twice as many—in the same amount of time.