Plasma Cutters

About Plasma Cutters

Plasma cutters are sophisticated cutting tools that use an accelerated jet of hot plasma to slice through electrically conductive metals with exceptional precision and speed. Unlike traditional cutting methods such as angle grinders or hacksaws, plasma cutting technology creates a clean, narrow kerf with minimal heat distortion, making it ideal for fabrication work, metal sculpture, automotive repairs, and general metalworking applications. These versatile machines can cut through steel, stainless steel, aluminium, brass, and copper with remarkable efficiency, transforming what would be laborious manual cutting tasks into quick, precise operations.

The selection at Tooled-Up.com includes complete plasma cutting systems alongside essential consumables and replacement parts to keep your equipment running at peak performance. From compact 25-amp units suitable for thinner materials and occasional use, through to robust 60-amp high-frequency plasma cutters capable of handling thicker steel plate, there are solutions for workshops of all sizes. You'll find everything from complete cutting torches to individual components including electrodes, nozzles, ceramic shrouds, and safety caps from trusted brands like Draper and Sealey.

Modern plasma cutters are considerably more accessible than earlier generations, with many models featuring high-frequency arc starting, thermal overload protection, and compatibility with compressed air rather than expensive bottled gases. Whether you're setting up a new fabrication workshop or maintaining an existing machine, having access to quality consumables and spare parts ensures minimal downtime and consistent cutting performance throughout demanding workdays.

Jargon Buster

• Amperage Rating: The electrical current capacity of the plasma cutter, typically ranging from 25A to 60A or higher. Higher amperage allows you to cut through thicker materials – a 40-amp unit can generally cut approximately 12mm steel cleanly.
• Duty Cycle: The percentage of a 10-minute period that the plasma cutter can operate continuously before requiring a cool-down period. For example, a 60% duty cycle means 6 minutes of cutting followed by 4 minutes of rest.
• Pilot Arc: An advanced starting system that creates a small plasma arc within the torch before the main cutting arc forms, allowing you to cut through painted, rusty, or scaled surfaces and start cuts without touching the workpiece.
• Consumables: Replaceable components within the plasma torch including the electrode (which creates the arc), nozzle (which focuses the plasma stream), and ceramic shroud (which protects internal components and focuses the gas flow).
• Cut Capacity: The maximum thickness of metal that a plasma cutter can effectively sever. Manufacturers typically list both a "clean cut" capacity and a "severance cut" capacity, with the latter being thicker but producing a rougher edge.
• High-Frequency (HF) Start: An ignition method that uses a high-voltage, high-frequency spark to initiate the plasma arc without the torch touching the workpiece, reducing consumable wear and improving arc stability.

Who Uses Plasma Cutters?

Plasma cutting equipment serves a diverse range of professional tradespeople and skilled enthusiasts:

• Fabricators and Welders: Metal fabrication shops rely on plasma cutters for precision cutting of steel components, brackets, and custom metalwork
• Automotive Technicians: Mechanics and restoration specialists use plasma cutters for bodywork repairs, exhaust modifications, and vehicle dismantling
• Agricultural Engineers: Farm workshops require plasma cutters for repairing machinery, cutting heavy gauge steel, and general maintenance work
• Construction Contractors: Site workers cutting structural steel, rebar, and metal framework for building projects
• HVAC Engineers: Heating and ventilation specialists cutting ductwork and metal sheeting with precision
• Metal Artists and Sculptors: Creative professionals creating decorative metalwork, gates, railings, and artistic installations
• Maintenance Engineers: Industrial facilities requiring quick, clean cuts for equipment repairs and modifications
• DIY Enthusiasts: Home workshop owners tackling metal projects, garden structures, and restoration work

How to Choose the Right Plasma Cutters

Selecting the appropriate plasma cutting equipment depends on several key factors that match the tool to your specific requirements:

Cutting Capacity and Amperage: Determine the maximum thickness of metal you'll regularly cut. A 25-amp plasma cutter suits sheet metal and materials up to 6mm, whilst 40-amp models handle up to 12mm steel effectively. For 60-amp units, expect clean cuts through 18mm mild steel. Always consider the "clean cut" rating rather than maximum severance for professional-quality results.

Power Supply Requirements: Check your workshop electrical supply before purchasing. Most domestic plasma cutters operate on standard 240v single-phase power from a 13A plug, but larger industrial models may require dedicated circuits or three-phase power. Consider machines with thermal overload protection to prevent damage during extended use.

Duty Cycle: Professional workshops need higher duty cycles (60-80%) for continuous operation, whilst hobbyists can often work within the constraints of a 35-40% duty cycle. The duty cycle directly impacts productivity and how frequently you'll need to pause work.

Starting Method: High-frequency start systems offer superior performance, particularly on painted or contaminated surfaces, and reduce consumable wear. Pilot arc technology is worth the investment for professional applications where reliability and cutting versatility matter.

Consumables Availability: Ensure replacement electrodes, nozzles, and shrouds are readily available and reasonably priced. Standardised consumables from established brands like Draper provide better long-term value and availability across the UK market.

Portability and Build Quality: Consider whether you need a portable unit for site work or a stationary workshop machine. Look for robust construction, adequate cooling systems, and comprehensive thermal protection for longevity.

Popular Accessories

• Replacement Electrodes: The heart of the plasma torch that creates the electrical arc. These wear gradually and require regular replacement to maintain cutting quality and arc stability.
• Cutting Nozzles: Focus the plasma stream for precise cuts. Different nozzle orifices suit various amperages and cutting applications, from fine detailed work to heavy plate cutting.
• Ceramic Shrouds: Protective shields that direct gas flow and protect internal torch components from spatter and heat damage whilst improving cut quality.
• Complete Cutting Torches: Replacement or spare torch assemblies including the handle, trigger mechanism, and consumable holders for different amperage ratings – available from Tooled-Up in various specifications.
• Safety Caps: Protective covers for torch tips that prevent accidental contact and damage to consumables during storage and transport.
• Air Filtration Systems: Essential for removing moisture and contaminants from compressed air supplies, extending consumable life and improving cut quality.
• Welding Screens and Curtains: Protect nearby workers from harmful UV radiation and bright plasma arc light in shared workshop environments.

Safety Information

Plasma cutting generates significant hazards that require proper safety measures and personal protective equipment:

Eye and Face Protection: Always wear a welding helmet with appropriate shade rating (typically shade 5-8 for plasma cutting) to protect against intense UV and infrared radiation. Standard safety glasses are insufficient protection.

Protective Clothing: Wear flame-resistant clothing, leather gloves, and steel-toe boots. Avoid synthetic fabrics that can melt. Ensure clothing covers all exposed skin to prevent UV burns similar to severe sunburn.

Ventilation and Fume Extraction: Plasma cutting produces hazardous metal fumes and gases. Work in well-ventilated areas or use local exhaust ventilation systems. Follow HSE guidance on exposure limits, particularly when cutting coated, painted, or galvanised materials which release toxic fumes.

Electrical Safety: Ensure proper earthing of equipment and workpieces. Never operate plasma cutters in wet conditions or with damaged cables. Installation should comply with BS 7671 wiring regulations, and consider having a qualified electrician verify your workshop electrical setup.

Fire Prevention: Keep a suitable fire extinguisher nearby (CO2 or powder type for electrical fires). Remove flammable materials from the cutting area, as hot metal particles travel considerable distances and remain dangerously hot.

Compressed Air Safety: Use properly maintained air compressors with adequate filtration. Never exceed the recommended air pressure for your plasma cutter, as this can damage equipment and create safety hazards.

Frequently Asked Questions

What thickness of steel can a 40-amp plasma cutter handle?
A 40-amp plasma cutter typically provides a clean cut through mild steel up to 10-12mm thick, with a maximum severance capacity of around 16mm. However, the quality of the cut diminishes as you approach maximum capacity, so for regular professional work, it's best to operate within the clean-cut range for optimal results and reduced consumable wear.

How long do plasma cutter consumables last?
Consumable life varies significantly based on amperage settings, material type, cutting technique, and air quality. Under ideal conditions with proper air filtration, electrodes might last 1-2 hours of arc time, whilst nozzles can achieve 2-3 hours. Poor technique, contaminated air supply, or excessive amperage dramatically reduces consumable life. Keeping a stock of spare electrodes, nozzles, and shrouds ensures minimal downtime.

Can I use a plasma cutter on stainless steel and aluminium?
Yes, plasma cutters work excellently on stainless steel and aluminium, as well as other conductive metals including brass and copper. In fact, plasma cutting is often preferred for aluminium over oxy-fuel cutting. The process remains the same regardless of metal type, though cutting speeds and consumable wear rates may vary slightly between different materials.

Do I need special gas bottles for a plasma cutter?
Most modern plasma cutters designed for workshops and light industrial use operate perfectly well with shop compressed air, eliminating the need for expensive bottled gases. Some professional applications benefit from nitrogen or argon-hydrogen mixtures for superior edge quality on stainless steel or thicker materials, but compressed air provides excellent results for the vast majority of general metalworking applications.

What size air compressor do I need for plasma cutting?
Check your specific plasma cutter's requirements, but generally, a 25-40 amp unit requires approximately 120-150 litres per minute at 5-6 bar pressure. A compressor rated at 14-21 CFM (400-600 l/min) with a decent receiver tank (50-100 litres) provides adequate supply. Crucially, include an air filter-regulator-lubricator unit or dedicated air dryer, as moisture and contaminants drastically reduce consumable life and cutting quality.