10 Best Plasma Cutters 2021 – Reviews And Buying Guide

Hey, do you have a project where you need to make clean, smooth and fast metal cuts? If you own a plasma cutter, it will save you from noisy polishing, rough cutting, dirty workplace and imperfect shape.

Plasma cutting has been constantly modified and worn since the 1960s from huge eyesore to stylish, compact, portable and methodical. The range expands in size and the same in price.

Top Best Plasma Cutters list 2021

Best Cheap Plasma Cutter Reviews & Comparisons

Advantages of the Plasma Cutter

1. One of the quickest ways to cut the material which is electrically conductive.
2. No need for preheating just set the torch and start cutting instantaneously. 
3. A useful addition to your shop floor as torches are precise and versatile.
4. One can perform cuts at complicated angles and shapes effortlessly.
5. The quality of the cut is clean, precise, and beautiful.
6. The equipment closely integrates the torch with its software for the laser-like cut.
7. A plasma cutter is incredibly easy to use, even by a novice fabricator.
8. Higher versions of plasma cutting machines are equally safe as they are fitted with exhaust to redirect the smoke away from the user.

Shortcomings of the Plasma Cutter 

1. When you need the unit for occasional metal cutting then this machine is not a choice as it is a specialized machine for your project. It is not worth a purchase if your cutting is not a regular feature.

2. It is more expensive than a grinder and hacksaw blade as an initial investment. In a longer period of time, it may not be expensive as its consumables are affordable and long-lasting.

3. Cutting through metal creates a warmth zone at the edges and may lead to the hardening of edges.

4. The dross formation is next shortcoming as the molten metal re-solidifies at the perimeter of the cut. This dross needs manual cleaning to offer a spotless and neat cut.

A Buying Guide – Plasma Cutter

What power levels will you need?

The power level you need from your plasma cutter depends upon the metal type and the thickness that is to be cut. The power output significantly influences the cutting quality, ability, and duty cycle of the model. Common models in workshops and homes run on 120V, 15A outlets but efficient high performance needs 20-50A and 220v.

The thickness of the metal is a big consideration while determining the power of the plasma cutter. The unit can cut any conductive metal from copper to steel. Plasma torch with 25 amperes cut perfectly up to 1/4inch, the 40A demanded to cut 1/2 inch while the minimum 60A required for 1-inch sheet thickness. 

Workout with your electric department to calculate your needs in a workshop or home. If you need to cut 1/2 inch metal plate, it requires the 220v output. Power output directly proportional to input power but choose the accurate power wasting no power input.

Cost vs Performance

Making a balance between performance and cost is a tough challenge. You have a limitation to spend the amount you have with you. The performance and quality of the product is the next challenge.

As a rule, determine the specifications you need in your plasma cutter. Make a list of the specifications that can fulfill your cutting needs. Enlist the model available and their specifications. Pinpoint the model that can achieve the cutting goal of your project. 

Do not spend a penny for the extra specifications which you do not need in your project. Eliminate the unnecessary features and accessories to curtail the cost without compromising the performance.

Never calculate the initial cost only for its unit only but consumables as well. The running cost is equally essential for cost-effectiveness.

Plasma Cutting for Learners

Your need as a beginner fabricator differs from the industrial units for heavy cutting. Hobbyist, artist, DIY’s generally need a high-performance model as the desired plasma cutter.

Better to evaluate your unique needs, as your project and capabilities. Impulsive buying can lead to clutter collection than to superb cutter collection. Choose the equipment as your ability permits. The potentiality is to perform and spend.

A beginner needs to consider the following points:

Assess the power output of the plasma cutting machine. It will ensure how much thickness and width we can cut by the purchased metal cutter. 

Select the model which is having its torch, a high quality, durable, versatile with a long span of life.

Consumables of Plasma Cutter

The parts of the unit which wear out with time are consumables. Plasma cutter has the following consumables:

• Nozzle
• Electrode
• Shield
• Retaining cap
• Swirl ring

The shield protects other consumables from molten pools and sparks. The retaining cap holds the consumable slack in position. Swirl ring directs the gas from the unit across the torch for the cutting. The electrode and nozzles are the fastest to wear out. The nozzle compresses the plasma arc and controls the gas flow. The electrode helps to ignite the arc for the plasma cutting.

A good quality air compressor is another essential to complete the process.

Various Applications of Plasma Cutting

Commercial Cutting in Industries

Plasma cutter plays a very essential role to make the manufacturing optimum and cost-effective. Whether you produce a single piece or mass production, cost and efforts should be kept in mind. When working on plasma or doing the conventional cutting, compare them.

Mounted Plasma torches lower the cost of cutting when during automation, cuts particular patterns. Not even they are faster but more clean, precise and lass dross is noticed. Industrial cutting does not allow a tiny error, so automated and programmed torches remove this risk.

The high-tech industrial process needs aesthetics and precision as prime importance. The initial cost of these plasma machines may be high, but the durability of the equipment and consumable needs a sympathetic consideration. This will reduce the effective cost of a longer time.

Artcraft Work Cutting

Artcraft is such a venture that without proper tools may be a frustrating experience to express themselves. To reach the level of creativity, artists with a plasma cutter are enabled to make minute, complex, and intricate cuts and designs.

The era before the plasma torch was tough for a metal artist to make a precise cut. The available source for cutting was inadequate to take control of their artwork. These torches empower the artist to make different intricate themes in solo or in mass production even.

The ionized plasma torch empowers an artist to fulfill his dream for the art of his choice.

Automotive Carriage Cutting

Automotive professionals, hobbyists, garage owners need plasma for automotive cutting for vehicular restoration, customization, and repair. The cutting needs include removal of parts, fabrication of new parts, nuts & bolts cutting, and preparing metal surfaces. Portability and lower weight is always the need for the automotive business.

The need is always for a handy, strong, versatile gun with a pilot arc to cut even rusty and painted surfaces in every small nook & cleft. The automotive cutting is generally a thin sheet not beyond 1/2″ thickness.

DIY’s or Home Fabrication

A homeowner may need a gun to cut metal for repair and maintenance. In a home, we can summarize various applications like plumbing, home welding repair, garage doors, fixture fabrication. 

The choice of plasma cutter with a long life, economical consumable cost is a better option where portability may be compromised.

Best Cheap Plasma Cutter Buying Guide

As there are a variety of plasma cutters available today, it can be quite confusing for you to pick one that’s best suited for your needs. That said, there are a few features that you need to consider before going forward with the purchase. Keeping these factors in mind will help you in finding the right tool for your needs.

Here’s a quick buyer’s guide showing you what you should pay attention to before buying a plasma cutter:

Power Source

This is a key factor to consider before you purchase a plasma cutter. These tools can use either electricity or air pressure to cut through metal. While both are equally powerful and feasible for most usage, knowing the power source for the tool is important. If the place you work at has limited electrical outlets, then air pressure models work best.

Regardless of which cutter you go for, it’s also important to know what gas type it needs to run. Also, make sure if the place you work at has 110V/220v power outlets. Moreover, you’ll need to see if the breakers at your workshop have adequate amps to resist the unit’s amperage and also the air compressor.

Understanding CNC Plasma Cutters

Plasma cutters are either handheld or CNC-operated.

Handheld torches are ideal for quickly cutting through metal plates, sheet metal, pipes, bolts, straps, and so forth. They are also good gouging tools, for back-gouging weld joints or removing defective welds. You can use a hand torch to cut small shapes from steel plate. However, it is not possible to achieve good enough accuracy or edge quality for most metal fabrication, which is why we need CNC plasma cutters

The CNC plasma system is a machine which moves its plasma torch in a computer-directed path. The computer directs the machine’s motion using numerical codes in a program.

Handheld vs Mechanized Plasma Cutters

CNC cutters typically use a different type of plasma system then the handheld ones. Their type of system is specifically designed for mechanized cutting rather than handheld cutting.

Mechanized plasma systems feature a straight-barreled torch, and an interface which can be controlled automatically by the CNC.

Some entry-level CNC machines can carry a torch designed for handheld cutting. However, machines designed for intensive manufacturing or fabrication tend to have a mechanized torch and plasma system.

Parts of the System

A CNC could be two things. It could be an actual controller specially designed for machine tools, featuring a proprietary interface panel and a specially designed control consol. On the other hand, it could be something as simple as a Windows-based laptop running a software program that communicates with the machines drives via Ethernet port.

Many entry-level machines, HVAC machines, and some precision unitized machines operate with a laptop or desktop computer as their controller.

The torch’s motions are controlled by the CNC. A part program, which is typically a text file containing M-codes and G-codes describes the part’s contours and instructs when to turn the torch on or off.

Part programs are typically written by a post-processor, which is a software that takes part geometry from a CAD file and translates it into G-codes and M-codes  that the CNC can read.

The CNC plasma cutter also needs a drive system. The drive system consists of motors, drive amplifiers, encoders, and cables. There should be at least two motors: for the X-axis and Y-axis. Each motor has its own drive amplifier, turns a low-power signal from the CNC into a higher-powered signal that indicates how far the axis has moved.

The motor receives the power from the amplifier via cables which also transport position signals from the encoder back to the CNC.

After reading the part program, the CNC outputs signals to the machine’s drive system. In response, the drive system causes the torch to move in the desired direction and at the programmed speed.

The CNC reads the feedback from the encoder, making necessary corrections to the drive signals to ensure the torch remains on the programmed path.

All the electronics that make up the CNC and drive system communicate and work super-rapidly. They measure and update position information every few milliseconds. As a result, the machine has a smooth motion that is accurate enough to produce plasma-cut parts that have a straight, smooth, consistent edge quality and precise part dimensions.

CNC plasma systems have an I/O system – that is an electrical system which handles inputs and outputs. It is that enables the CNC to turn on the plasma at the appropriate time – for instance by turning o an output that closes a relay. The CNC uses inputs to know that the plasma arc has started and is ready for movement. These are the basic necessary inputs and outputs, but there can be many more.

There are many features and subsystems. These include arc voltage height control systems, integrated plasma systems, plasma bevel systems, and so forth. However, the features we have described above are the basics of a CNC plasma cutter and as such are common to all CNC plasma machines, even the simplest ones.

Conclusion

A plasma cutter is an important tool for any person working with metal. It is a bewildering prospect to select a piece of equipment that is new to you with so many plasma cutter brands and models to choose from. They come in many models, sizes and amperages. If you answered all the questions above, you will end up with the best plasma cutter that is right for you!

Frequently Asked Questions

How do you set up a Plasma Cutter?

The plasma cutting is based on the principle of complete electric current, so the need for a ground clamp is there. Choose the safe work surface in your workshop where you can move around the work table freely. 

Time to plug in the machine after ensuring the compressor is around. Attach the compressor to the metal cutter and examine the continuous flow of the air pressure.

Now place your workpiece over the table and connect a ground clamp to the workpiece as near as possible for the best results. Switch on the unit by flicking and pressing a switch on the unit marked on/off or power.

What is possible to cut by plasma cutting?

The plasma cutting is possible with any electrically conductive metals because there will be a complete electric current circuit through a workpiece and ground clamp. 

The electric current generates an arc and the heated arc melts the metal to ionic plasma form. The plasma propagates and increases its speed once passes through an orifice. The air pressure in turn blows away the molten plasma metal and produces a very clean and precise cut. 

The user can cut through metals like copper, aluminum, brass, and stainless steel. It can cut any electrically conductive material.

Should I purchase a Plasma Cutter online?

There is no harm in purchasing a plasma metal cutter online. Most of the online stores offer free shipping. They generally offer free accessories at online purchases. 

Brick and mortar stores can display 10-15 models, while online stores display hundreds of products online. The choice becomes wider and so the purchase.

The reviews of the previous purchaser may help you know the material better. 

Can we cut wood or plastic with a plasma cutter?

No, it is not possible to cut the nonconductive materials. Wood and plastic are electrical resistance materials.

The metal thickness is the prerequisite to the current setting and air pressure maintenance.  Bring the nozzle near to the metal and pull the trigger to start the cutting.

How much faster is a plasma cutter?

The most effective means of metal cutting is plasma cutting. It is possible to cut 200 inches of metal per minute by a good plasma cutter. 

The people are working on the technique to improve the speed further. The better speed, the better production is the aim.

Is a cheap plasma cutter worth it?

If you purchase a cheap plasma cutter, please do not expect adequate power, durability, and optimal quality. The thinner sheet may work better with a low price plasma cutter.