Can a Plasma Cutter Cut Expanded Metal? A Complete Guide
Expanded metal, grating, and perforated sheet can be challenging to cut because the arc repeatedly encounters open spaces. Fortunately, most Hypertherm Powermax® plasma systems include a Continuous Pilot Arc mode that makes the process fast and easy. Additionally, Hypertherm offers the HyPilot cartridge that dramatically extends consumable life for these applications. Combined with Continuous Pilot Arc mode, Hypilot and Powermax are a perfect setup for cutting expanded metal. .
Below are answers to the most common questions about cutting expanded metal with a plasma cutter.
Can a plasma cutter cut expanded metal?
Yes.
Plasma cutting is one of the best methods for cutting expanded metal because it can quickly move across openings without damaging surrounding material. Most Powermax® air plasma systems feature a Continuous Pilot Arc mode that automatically switches between cutting current and pilot current as the arc encounters holes. This allows the arc to remain active and increases overall productivity.
What is Continuous Pilot Arc (CPA)mode?
Continuous Pilot Arc, or CPA, mode is a feature available on many Hypertherm Powermax® systems.
When activated, the system rapidly alternates between:
-
Cutting current when over metal
-
Pilot current when passing over open spaces
This allows the torch to maintain the arc instead of repeatedly extinguishing and restarting.
Benefits include:
-
Easier cutting
-
Faster operation
-
Improved productivity
Which Powermax® systems have Continuous Pilot Arc mode?
Many Powermax systems include this capability.
Examples include:
-
Powermax65 SYNC
-
Powermax85 SYNC
-
Powermax105 SYNC
-
Powermax125
Additionally, the Powermax30 AIR, Powermax30 XP, and the Powermax45 SYNC operate with a continuous pilot arc at all times. Refer to your operator manual or product specifications to confirm whether your system includes Expanded Metal mode.
Why do some Powermax systems have a mode for Continuous Pilot Arc while others have it on all the time?
When piloting, the nozzle in the consumable stack-up or cartridge is stressed more than when cutting. This can cause a reduction in overall life. By shutting off Continuous Pilot Arc mode, the consumables can last longer in applications that do not require continuous cutting.
How do I cut expanded metal with a hand torch?
Cutting expanded metal manually is simple:
-
Select Continuous Pilot Arc mode.
-
Place the torch on the material.
-
Pull the trigger.
-
Maintain a steady travel speed.
-
Complete the cut.
No special consumables are required, but using the HyPilot cartridge with NickelPlus technology will significantly extend consumable life when cutting expanded metal.
How do I cut expanded metal on a CNC table?
Mechanized cutting requires one important adjustment:
Turn off torch height control (THC).
When the torch passes over openings, the arc voltage changes. If THC remains active, the torch may:
-
Dive into the workpiece
-
Lose height control
-
Produce poor cut quality
For best results:
-
Disable THC.
-
Maintain a fixed torch height.
-
Use Expanded Metal mode.
-
Use the recommended cut speed for your material.
Why does my torch dive when cutting expanded metal?
Torch diving is almost always caused by torch height control remaining active.
As the arc passes over holes, the control system interprets the voltage change as excessive torch height and lowers the torch.
Turning off THC prevents this behavior.
Can I cut perforated metal with the same settings?
Yes.
Continuous Pilot Arc mode works well for:
-
Expanded metal
-
Grating
-
Mesh
-
Perforated sheet
The same principles apply:
-
Enable Continuous Pilot Arc mode.
-
Disable torch height control during mechanized cutting.
-
Maintain the proper stand-off distance.
-
Use sufficient travel speed.
How thick of expanded metal can a plasma cutter cut?
Cut capacity depends on the plasma system being used.
For example:
| System | Typical Expanded Metal Capability |
| Powermax30 XP | Thin sheet and light gauge |
| Powermax45 SYNC | More than 5/16 in. (8 mm) |
| Powermax65 SYNC | Thicker material |
| Powermax85 SYNC and 105 SYNC | Heavy-duty applications |
Always follow the recommended cut capacity specifications for your system.
Why does my arc go out while cutting expanded metal?
Possible causes include:
Travel speed is too slow
If the torch spends too much time over open spaces, the arc may extinguish.
Continuous Pilot Arc mode is not enabled
Without this mode, the arc must repeatedly restart.
Torch height control is still active
THC can interfere with arc stability.Improper stand-off distance
Maintaining the recommended torch-to-work distance helps improve performance.
Do I need special consumables to cut expanded metal?
No. But Hypertherm offers the HyPilot consumable- this consumable is engineered to allow for excessive piloting, which happens with expanded metal cutting, without burning out your nozzle as quickly.
Additionally, using:
-
Genuine Hypertherm consumables
-
Proper amperage settings
-
Clean, dry air
Will help maximize consumable life and maintain cut quality.
What should I do when I'm finished cutting expanded metal?
Switch the machine back to normal cutting mode.
Leaving the system in Continuous Pilot Arc mode during regular plate cutting can shorten nozzle life and reduce consumable performance.
Frequently Asked Questions
Can a plasma cutter cut expanded metal?
Yes. Plasma is one of the easiest and most efficient ways to cut expanded metal.
Should torch height control be turned off?
Yes, for mechanized cutting.
Can I cut perforated metal?
Yes. Expanded Metal mode works well on perforated material.
Do I need special consumables?
No. But Hypertherm offers the HyPilot consumable.