Hypertherm Associates Expands XPR Plasma Cutting Features for Added Productivity and Versatility

HANOVER, N.H.— September 8, 2025—Hypertherm Associates, a U.S.-based leading manufacturer of industrial cutting systems and software, has announced enhancements coming to its Hypertherm XPR platform by the end of the year, including a new streamlined modern design, featuring IIoT capability, Manual Set-mode, automated gouging capability, Vented Water Injection processes, and improved True Bevel™ technology for thicker, more precise bevel cuts.

XPR enhancements

The new control board enables Ethernet LAN capability for IIoT connectivity and robust access to the XPR interface tool. It also incorporates MTConnect^® communication protocol for data exchange between machines and software applications for machine monitoring and process analysis. This capability puts cutting data at the operator’s fingertips and allows remote plasma system monitoring from anywhere in the world.

For straightforward applications that do not require sophisticated integration with a CNC/PLC such as gouging and off-table beveling, XPR now features a Manual Set-mode—perfect for repetitive jobs using the same plasma process. Even after a power cycle, the system remembers the last setup, keeping operations smooth and efficient.

The new XPR gouging capability radically decreases the time needed to get weld-ready parts with wider, deeper, cleaner, and consistent gouge profiles that need little, or no clean-up compared to traditional gouging technologies.  Compared to carbon arc or low-amp plasma hand gouging, XPR automated gouging on a robot, cobot, or track-guided motion control reduces labor and increases productivity by speeding up weld-prep for high-precision welding applications. XPR gouges further from the plate, reaching hard to access and tight spaces with an extended arc stretch and higher arc transfer height.

XPR460 boosted capabilities

In addition to these XPR platform enhancements, Hypertherm boosted capabilities for the XPR460 with 460A Nitrogen/Vented Water Injection (VWI) for high-quality cuts with smooth surfaces on thick stainless steel and aluminum. New 460A Y-Top True Bevel™ capability for thicker mild steel increases accuracy and quality consistency, eliminating machine operator guesswork.