Plasma Cutting vs. Laser Cutting: Which to Use

When producing precise, high-quality cuts on various materials, the decision often comes down to plasma and laser cutting.

Despite sharing the ultimate goal of cutting materials, these two methods vary significantly, leading to different advantages and disadvantages This article compares these two popular cutting processes across key factors: speed, cost, precision, and material versatility. By doing so, we aim to help you make informed decisions based on your project needs.

Let’s explore how they compare.

What is Plasma Cutting?

Plasma cutting is used to cut electrically conductive materials like steel, stainless steel, aluminum, brass, and copper.

The process employs an accelerated jet of hot plasma channeled through a focused nozzle toward the workpiece. A completed electric circuit is formed by creating an electrical arc within the gas between an electrode and the workpiece. The electrical arc ionizes the gas, forming an electrically conductive plasma channel. As electricity travels down this plasma, it generates enough heat to melt through the workpiece, enabling cutting.

What is Laser Cutting?

Laser cutting is a technology predominantly used in industrial manufacturing. It employs a high-power laser to slice materials.

The laser beam either melts or vaporizes the material it touches. A gas then blows the molten material from the kerf, ensuring a clean cut. The power from the laser, concentrated over a small area, allows for high-precision cutting at high speed. Different types of lasers are used based on the specific type of material.

Speed

Plasma Cutting: Plasma cutting is known for its speed, particularly when cutting thicker materials. It can typically outperform laser cutting when cutting materials over 10mm thick.

Laser Cutting: Although generally slower than plasma for thicker materials, laser cutting excels in speed when dealing with thinner materials. It is particularly suitable for high-speed cutting of thin sheet metals and non-metals.

Precision

Plasma Cutting: While plasma cutting can achieve a high level of accuracy, it typically cannot match the precision of a laser cutting system. This is particularly noticeable when dealing with fine features or intricate designs on thinner materials.

Plasma cutting in action

Laser Cutting: Laser cutting offers superior precision and a smaller kerf width, which allows for more intricate designs and sharper corners. This high precision makes it ideal for applications requiring exceptional detail and accuracy.

Cost Comparison

Plasma Cutting: Generally, plasma cutting systems are more cost effective to purchase and maintain. The process also operates at higher speeds, which can significantly lower operational costs for certain projects when cutting thicker materials.

Laser cutting in action.

Laser Cutting: Laser cutters, especially fiber lasers, can be more expensive initially. However, they offer more precise cuts and can be more cost-effective when dealing with thinner materials due to reduced waste and lower post-processing requirements.

Material Versatility 

Plasma Cutting: Plasma cutting is excellent for cutting any electrically conductive materials, including mild steel, stainless steel, aluminum, copper, and brass. It’s particularly adept at cutting thicker materials quickly.

Laser Cutting: Laser cutting systems can cut various materials, including metals, plastics, wood, glass, and more. However, they excel at cutting thin to medium-thickness metal plates.

Getting Started

Whether it’s plasma or laser cutting, the decision largely depends on your project requirements.

Regardless of your cutting needs, remember that understanding both these technologies’ advantages and potential limitations is crucial for making an informed decision.

For more help deciding which cutting method is best for your project, our experts at MakerVerse are here to help. Explore our range of cutting technologies and material options, or work with one of our experts to find the best solution for your needs.