When it comes to choosing the right plasma cutter, making an informed decision can be challenging, especially with a variety of models and specifications available in the market. In this comprehensive guide, we’ll break down all the factors you need to consider to select the best plasma cutter for your specific needs.

What is a Plasma Cutter and How Does it Work?

A plasma cutter is a versatile tool that uses an electric arc to ionize gas, creating a plasma stream capable of cutting through various types of metal. The plasma cutter functions by sending a high-velocity jet of ionized gas (plasma) through a nozzle. This gas melts the metal, and the force of the gas flow blows the molten metal away, leaving a clean cut. Plasma cutting is used across a wide range of industries due to its efficiency, precision, and versatility in handling different metals.

Key Factors to Consider When Choosing a Plasma Cutter

1.Material Type and Thickness

A plasma cutter must be powerful enough to cut the material you are working on. Plasma cutters can cut any conductive material, including steel, stainless steel, copper, and aluminum. It is important to know the materials you work with most often, as the thickness of the selected material will affect which plasma cutter to choose based on amperage.

Unlike welding, plasma cutting requires relatively high voltage and low amperage, so finding a plasma cutter with the correct amperage is key to cutting thicker materials. Purchasing a plasma cutter that does not provide enough power for your task may slow you down and complicate your project.

2.Input Voltage

Plasma cutters come in three main voltage options: 110V, 230V, or dual voltage. For beginners using a standard household outlet, 110V should be enough, but if you’re looking for a more powerful machine, you may want 230V. Decapower’s plasma cutters offer dual voltage inputs, providing versatility for a variety of work environments.

3.Duty Cycle

Duty cycle refers to the amount of time a machine can run continuously in a 10-minute period. For example, a plasma cutter with a 70% duty cycle and 50 amps can run for 7 minutes in a 10-minute period, but will need at least 3 minutes of downtime to maintain a safe operating temperature. If the user attempts to cut for longer than the rated duty cycle, the plasma cutter may reduce power or shut down completely.

Ideally, a plasma cutter would have a 100% duty cycle at the required current so that delays do not have to be accounted for during motion planning. However, most low-cost plasma cutters have a duty cycle of about 40% to 60% at their maximum rated power, and the user must be careful not to cut for too long. Generally, a higher duty cycle can be achieved using less power (lower current). If you want to cut at 40A (up to 3/8-inch material), it is recommended to purchase a plasma cutter rated at 55A to achieve a higher duty cycle at 40A.

4.Internal or External Air Compressor

For light-duty cutting, some plasma cutters have built-in compressors that can provide enough compressed air. This makes plasma cutters more portable and easier to use. Let you cut anywhere, anytime, but with limited power and time.

For larger jobs, an external air compressor is usually necessary. As a rule of thumb, choose a compressor with a flow capacity at least 1.5 times the consumption rate of the plasma cutter.

Some advanced devices allow you to use both at the same time, such as the PILOT CUT KZ series from Decapower. With an inbuilt small compressor, it’s very convenient for taking anywhere for clean cutting plate thickness up to 1/2″. For cutting thicker plates, you can switch to an external compressed air source, up to 5/8″(40A), and15/16″(60A).

According to your cutting needs, you can make very flexible choices to bring you the greatest convenience in metal cutting.

5.Pilot Arc vs. Non Pilot Arc Plasma Cutter

Many plasma cutters on the market offer piloted arc technology, including the decapower plasma cutters. However, non-piloted arc plasma cutters are less expensive and we also have these models.

Summary of Key Differences

A common assumption is that if a plasma cutter has a pilot arc, then it is low frequency. This is NOT the case. Low and high frequency plasma cutters can have pilot arcs.

6.Portability

Portable plasma cutters are usually designed to be light and compact for easy movement. While most plasma cutters on the market are light, some are lighter than others. For example, in the 20Decapower, many models weigh between 15 and 48 pounds (about 7 to 22kg) with handles or built-in air compressors that support dual voltages.

7.Additional Features

When choosing a plasma cutter, various additional features can enhance its performance.

2T/4T: It brings you more comfortable operation during thecutting.

Post Gas：After cutting, the post-flow could accelerated cuttingsurface cooling.

Mesh Cutting: As it’s non-contact arc striking characteristic, thepilot cut machine allows cutting the mesh very easily

Do You Need Gas For Plasma Cutting?

Yes, plasma cutting requires gas to create the plasma arc that cuts through the metal. The most common gas used is compressed air, but oxygen, nitrogen, argon, or hydrogen can also be used, depending on the material or cutting application.

Oxygen: Oxygen has become the industry standard for cutting mild steel because it provides the best, cleanest, and fastest cuts of all the plasma gases.

Nitrogen: Nitrogen is the best choice when cutting aluminum and stainless steel, providing excellent cut quality.

Argon: Argon is ideal for cutting thick stainless steel and aluminum because it is the hottest burning plasma.

Compressed air: This is the most common and cost-effective gas used to create the plasma, and is also used to blow away the molten metal during the cutting process. For most applications, compressed air is sufficient.

Frequently Asked Questions (FAQs)

1.What materials can a plasma cutter cut?

A plasma cutter can cut any electrically conductive material, including steel, stainless steel, aluminum, brass, copper, and more. However, it cannot cut non-conductive materials like wood, plastic, or glass.

2.Is using a plasma cutter easy?

Plasma is Easy to Use, especially with models designed to be user-friendly. However, having some basic knowledge of the equipment and experience can improve your efficiency and safety.

3.Can I use a plasma cutter with a CNC machine?

Not all plasma cutters can be used with a CNC table. When choosing a plasma cutter, check if it has CNC compatibility features or if any modifications are required to integrate it. Decapower PILOT CUT 65 CNC is an impressive machine that has a CNC port on the back of the machine and can easily cut 4/5″ mild steel. The quality of the cut is simply amazing for the price, you won’t find a better machine than this price.

4.Are plasma cutters portable?

Yes, many plasma cutters are designed to be portable. Models with built-in compressors are the most portable, but even those that require external compressors can still be lightweight and easy to transport.

5.How thick can a plasma cutter cut?/How thick of metal can a 40 amp plasma cutter cut?

The maximum thickness of the material you plan to cut will determine the amount of current you need for your plasma cutter. Generally speaking, a 20A cutter can cut 1/8″ (about 3.175mm) material, and the capacity will increase by 1/8″ for every 10A increase in current. For example, a 30A can cut 1/4″, a 40A can cut 3/8″, and so on. In addition to being able to cut thicker sheets, a power supply that produces a more intense plasma (higher current) can cut thinner materials faster. Therefore, it is recommended to purchase a plasma cutter with a higher current that is within your budget.

6.Can A Plasma Cutter Cut Through Paint？

In fact, a plasma cutter can cut most metals, whether they are painted or rusted. If you purchase a cutter equipped with Pilot Arc Technology, even a coat of paint won’t cause any problems.