Best Plasma Cutter [110V/220V] Reviews & Buyer’s Guide 2024

Best Plasma Cutter – Buying Guide

The products that we placed on our list have been comprised based on our own professional opinion. But to help you get a better understanding of which one to choose, we also have a buyer’s guide that is sure to provide added insight and a better understanding of what to look for.

What is Plasma Cutting?

Plasma cutting is an operation that uses a melting process where a jet of ionized gas heated up to temperatures above 20,000°C is used to melt and expel material from the cut. Similar to some welding processes, an electric arc is struck between an electrode and a workpiece.

The electrode is recessed in a gas nozzle which constricts the arc and causes a narrow stream of high-temperature plasma to come out of it. Once the plasma touches the workpiece, the gas will revert to its normal state as recombination takes place. Further on, the heat melts the metal as the airflow ejects it from the cut.

Plasma Cutting Benefits

Once you go plasma you never want to go back to either oxy-acetylene cutting or mechanical cutting. All you need is one simple swoop of a hand and the cut will magically appear. There are many benefits that only plasma cutters have as opposed to all those conventional cutting processes.

• It produces much faster cuts.
• You don’t need to pre-heat.
• You can literally cut any type of metal that conducts electricity.
• Minimize the heat-affected zone

Operating a plasma cutter is also very simple. In fact, it is so simple that it will take you more time to choose the correct machine for you than to learn how to use it.

Learn how hot is plasma here.

Input Power and Power Source

The first thing to look at when you are buying a plasma cutter is the power outlets and power source you have at home. You will need two power sources to run a plasma cutter. The first one is for the machine itself and the second one for the air compressor to provide pressure. There are plasma cutting machines that come with an air compressor integrated within the machine so there is that option.

Voltage and Power Input

You also need to pay some attention to the form of electrical input that your plasma cutter will need. The more powerful and one can say heavy-duty industrial cutters use three-phase 480/277 V supplies.

The most affordable plasma cutters and most suitable for home or small shop purposes will use US standard of 110/120V, 220/240V, or a dual supply that allows both types of input. The only place you’re likely to find a three-phase machine is in an industrial setting. In most instances, it’s more useful to have a dual supply of 100v/200v.

240v/220v Plasma Cutters

If you need this voltage, you’re going to have to install a power-point designed for this type of supply.

That means spending more, if you want to cut through thicker materials though, you’re going to have to invest in this supply. You will of course also find that you cut faster and of a much higher quality with your plasma torch than on 110/120 Volt.

Do You Need an Air Pressure Source? (Air Compressor )

Using a plasma cutter with a built-in air compressor comes with various benefits. First of all, having an air compressor improves the quality of cutting and especially precision. The more pure the flame is the cleaner the cuts are. You can also adjust the pressure coming out of the tank and replicate the situation that suits you the most.

Secondly, built-in air compressors allow for more portability. If you are using a machine that has an air compressor separate from it, it will become much more difficult to move it around. Creating a lot of problems around the workshop.

However, the biggest advantage of plasma cutters with a built-in compressor is that it is a lot cheaper. The ones with an added compressor may be easier to move, but it is also going to be more expensive for your budget.

Power output is also an advantage of cutters with a separate compressor. Those with a compressor do not have to boot up the unit or feed it with constant power. It may not affect your power bill so much but it certainly affects the potency of a machine.

Power Required, Plate Gauge And Material Thickness

You will find that most cutters can cut through almost any kind of metal surface. However, it’s the thickness of the plate that they can cut that should determine the plasma cutter that you buy.

The rule is simple: the thicker the plate you want to cut, the more amps you will need. This determines your power needs.

You can cut through different gauges of plates based on the amp and the type of metal with your plasma torch. So, let’s say your plasma cutter can only cut 3/8″ of alu plate, it will be able to cut through 1/2 inch of stainless steel and up to 5/8″ of Metal sections.

In my experience, it’s always best to factor in some room between the machine’s maximum stated cutting width limit and the plate thickness you need to cut. In most cases, you won’t get a tidy cut if you try it at the maximum level and you won’t get the job done if you need to cut through something thicker.

Rated Duty Cycle

A duty cycle is basically the time a machine is able to work properly without overheating. All electrical equipment comes with one and so does a plasma cutter. It is measured within a 10-minute span, 10 minutes being the maximum or 100% that it can successfully go. So if a unit is labeled with a 30% duty cycle, it means that it will be able to operate for 3 minutes after which you will need to leave it to cool down.

When it comes to choosing a plasma cutter with an adequate duty cycle, hobbyists or people cutting around the house will not need more than a machine with a 50% duty cycle. However, if you are going to do some mechanized cutting you will probably need to cut for longer periods of time at which point 5 minutes are not going to be enough.

Advanced Features And Do You Need Them?

Like any type of welding and cutting equipment, plasma cutting devices come with certain advanced features. Professionals are going to have more use of these added features, but that is not to say that hobbyists can’t use them.

Unfortunately, machines with advanced features also cost more money. So depending on your needs, you will have to determine – how badly do you need all those features? Are there some that you can do without? Does it really worth investing more money in advanced features?

Automatic Torch Re-Strike

This feature allows all kinds of useful additions to your work. With it, you can achieve a machine-like “U” or “J” when working on heavy plates, round or flat surfaces. At lower costs, it can groove, bevel, gouge, and of course, cut any type of material. With it, you can create a better kind of finish than with any older method. You can also speed up fabrication by being able to prepare both plates at the same time.

Automatic Air Flow Adjustment

To put it simply, this is a torch power system that includes a compressor and a controller configured to adjust the output of a compressor in response to feedback comprising of the compressor output. It also includes adjusting the operational parameters of a torch unit to account for environmental conditions that might affect the performance of the torch.

The torch power unit might include a plasma cutting circuit, paired with a compressor, a motor, and an interface with a plasma torch connection. A compressor and an environmental feedback controller are fitted to adjust power output or compressor output.

This system might help the plasma cutter to function better when affected by outside conditions. The pressure and airflow are not going to be impeached and the danger of overheating is lessen.

Computer Numerical Control

Computer numerical control is one such advanced feature that enables this kind of cutting. You can adjust the settings as precisely as possible and get some really good results. However, CNC is a feature not often seen on regular machines.

If you want a machine that has it, you have to spend more money. In fact, things can get really expensive here so you have to determine whether you really need it or not.

Types of Torches and Arc Start To Consider:

A variety of torches also come into the mix. You can’t go with just any old thing as consideration is still needed.

High-Frequency Start (HSV) vs Mecanincal Blowback Start (NH)

A plasma torch requires a way to heat up the gas so it can reach its ionized temperature. The gas is then heated until it becomes electrically conductive resulting in DC energy coming from the power supply to superheat the air and turn it into a plasma gas that eventually creates a high-temperature cutting process.

There are two ways currently used to ionize the gas in a torch – High-Frequency, or high voltage discharge, and Contact Start also called the blowback start method.

1. High-Frequency Start – HSV

This type of cutter discharges a lot of electrical noise inside the work environment. Certain CNC machines that use a standard PC as a controller have problems created with electrical noise interference that the starting method causes. To combat these problems, modern CNC machines have complex grounding and filtering that allow the frequency to go without a hitch. And modern handheld plasma cutters are made in a way to bypass this problem altogether.

You will have no problem buying the plasma cutter that works on high-frequency technology if you get one from the top brands or if you make an inquiry with the manufacturer about these problems.

2. The Contact Start or Blowback Start (NH)

This method, as well as the HF, start one, is used to cut through rusty, dirty, and even painted materials. These methods are used predominantly by units in today’s industry for both hand and mechanical cutting operations.

Many welders prefer one of these two types of starting plasma cutters but both are good and you will not make a mistake with either one, especially when it comes to machines for hobbyists.

Pilot Arc vs Non-Pilot Arc

When it comes to using pilot arc, it can be attached to both machines with no touch start and those with blowback start. A pilot arc is a high-intensity arc that fires in the air. These types of torches work particularly well when transferring the arc to rust or painted surfaces. Having a pilot arc makes cutting any materials a lot easier, to say it simply.

1. Plasma Cutters With Pilot Arc Torch

2. Plasma Cutters With Non-Pilot Arc

Plasma Cutter Standoff

Also, it allows you to stand the torch while following a pattern. Finally, since the tip of the torch is not making contact with the surface, the backsplash is also avoided.

The main reason why a standoff is used is that it makes it a lot easier to glide the torch above a sheet of metal without having to touch the metal with the torch.

The best part comes with using a pilot arc torch when cutting rusty or painted metals as you don’t have to clean the surface you are working on.

Cut Finish and Cutting Speed

Knowing the exact cutting speed for the thickness of the material that you need to work on basically determines production rates. This is usually determined in parts per hour and manufacturers usually provide a cutting speed chart to go along with their machines.

Having a chart allows you to compare cutting speed performance. However, there are no universal standards and comparisons are facilitated with two types of standards – rated cut and sever cut.

Cutting speed chart

Rated Cut

The A-rated cut is the thickness of the material that the operator can cut manually at a rate of 15 IPM. This should be considered as a minimum speed that the operator uses to achieve a smooth and steady cut with the best possible quality.

Sever Cut

When it comes to a severe cut, it is the rating at which the operator pushes the machine to its maximum limits and a thickness of around 1-1/4 inches for a 55-amp unit. This results in very slow cutting speeds and it will usually require more clean-up afterward. Luckily, the speed will increase as the material gets thinner.

Required Consumables and Parts

Experienced cutters know just how valuable consumables can be when making quality cuts. But some that are not familiar with this concept, failing to realize how important the relationship between consumable components actually is. A single faulty component can misalign everything and cause the entire system to suffer.

When it comes to a plasma torch, there are five integral consumables to consider:

• The shield – There are a lot of sparks and molten metal flying around while plasma cutting. The shield helps to protect the rest of the consumables.
• Retaining cap – This part is used to hold the rest of the consumables together and is fixed on top of the stack up.
• Nozzle – This part is used to primarily focus the plasma arc and to funnel the gas flow, shaping and constricting the arc at the same time.
• Electrode – The electrode helps to carry the current from the torch to the plate.
• Swirl ring – This part is used to help channel the gas in various directions as it comes down the machine and to the torch.

Plasma Cutter Torch Maintenance

Taking care of your plasma cutter will help it work properly and last longer. The main issue comes with consumables that you are needed for a cutter as they have to be swapped out if they get faulty. Most machines come with a chart or a diagram of consumables that it comes with and which you are going to be using. It makes it a lot easier when you need to order spare parts.

the first part is the swirl ring that helps direct the air down to the torch. Next comes the electrode which is usually made out of tungsten. If you notice a pit of at least 1mm, it means that you have to throw the electrode out. Be sure to have the correct nozzle for the system that you are using. If your nozzle starts getting an elliptical hole or you notice some burns, throw that baby away and change it. This part shouldn’t make contact with the material because it may tear the orifice of the nozzle and ruin the cut quality.

It is near impossible to mess up the way you stack your consumables together. The torch will simply not work and you will get an error code on your machine that will prevent you from trying.

Different Plasma Cutting Uses

As the name suggests, plasma cutting is mainly used for cutting materials. But which types and for what kind of cutting?

Autobody Repair and Automotive Cutting

A plasma cutter comes more than useful when doing some autobody repairs. A machine with a cut rating of 3/8 inch and a sever rating of 5/8 inch is perfect for automotive fabrication. If you plan to work on thicker pieces of metal, a more powerful machine should be used.

If you happen to need to do any repairs on your car or around your house, a small plasma cutter with the mentioned parameters above is perfect. You don’t really need a more powerful one.

Industrial Cutting

Plasma cutting is very useful in industrial cutting. Since machines are able to provide precision cuts at low cost it is very much applicable in industrial CNC work. However, although these machines do exist they are not really useful for a hobbyist or a person who needs repairs around a home.

The units described above are aimed at smaller types of projects and home use. They are not going to be suitable for industrial work. At the same time machines that are more powerful and that come with CNC features are much more expansive. Investing in a machine like that for home use is not a good idea, that is why a list with all the machines above does exist.

Artwork Cutting

Using a plasma cutter doesn’t have to be all work. It can be fun as well and can help you produce fabulous pieces of art. The metal artwork is very much a thing and there are many people that have been able to hone their skills and turn it into an art form.

A plasma cutter is a basic instrument needed to cut some metal up and turn it into pieces that can become fabulous art pieces.

Small Welding Shop or Home Repair

A plasma cutter is a useful piece of equipment if you own a small welding shop or for certain home repairs. In fact, a combo machine that can cut as well as TIG/Stick weld is much more useful to have. Being that you are working in a small shop, it means that you are more than likely not going to work on any serious projects. So this type of combo machine could be useful.

However, don’t expect it to cut thicker pieces as it is simply not meant for that. But if your work consists of only home repairs or cutting something up for your neighbor, particularly if you reside in a rural setting, this type of combination will be perfect for the job.

Portability

Doing work around a house or within a small welding shop also requires maneuverability. Small projects do not require so much power but do need to be more mobile. Thus lighter machines have an advantage here.

Machines with built-in air compression account for more maneuverability but can be more expansive for your home shop. CNC machines are also expensive and are not really suitable for smaller applications.

What you need to aim for when getting a cutter for home use is for it to be suitable as a hand-held device, to be lighter, of compact size, and for it to automatically connect to 115V or 230V primary power.

Performance vs Price

But if your welder is going to go through a lot of abuse and you are planning to use it quite often, then investing a bit more money is a good idea. You still need to maintain it though, but the machine will be able to endure more wear and tear over time as it has more quality.

Warranty

When it comes to warranty, the basic rule, and the sanest one, is choosing a company that offers a better and longer warranty. However, you should also consider a brand that has better customer service.

If they are polite? Are able to meet your needs and answer complaints? More so, if they are kind enough to send replacement parts if you happen to need them, this is the brand to go with. So consider the warranty and customer care at the same time.