Are you in the world of metal fabrication? Choosing the right power supply can make a significant impact on the quality of your work. The decision to purchase a plasma cutter is about more than the type of work you intend to perform. Several factors make plasma cutters a good choice for busy manufacturers, DIY, artists, and small workshop cutters who wish to upgrade fabrication processes by adding precision, speed, and capability.  

This guide provides insights into some crucial questions to consider before selecting a plasma cutting system tailored to your requirements. 

Table of Contents: 

1. What material can be cut with a plasma cutter? 
2. How much is a portable plasma cutter? 
3. Why is the duty cycle important?  
4. Are plasma cutters portable? 
5. What power is needed? 
6. What PPE to wear for plasma cutting? 

1. Ideal Materials for Plasma Cutting   

Steel and aluminum alloys are considered ideal for plasma cutting. Both contain highly conductive properties. Electricity and heat can flow through Brass and copper similarly, due to how heat dissipates over these materials, specialized techniques and consumables can be employed to cut similarly to titanium, and anything with thermal conductivity or resistances drastically different from steel and aluminum alloys. 

2. Cost Considerations: Plasma Cutter Pricing 

Portable plasma cutting machines priced under $500 are often designed to be smaller and more compact, making them convenient for lighter cutting tasks or simpler projects. However, machines that boast higher amperage levels, durable duty cycles, precise cutting technology, compatibility with CNC systems, and a reputable brand can command prices as high as $20,000. Typically, machines that offer this comprehensive set of features tend to average between $3,000 and $5,000 in cost. These mid-range machines strike a balance between performance, advanced capabilities, and affordability for various cutting needs. 

3. Understanding the Significance of Duty Cycle 

Duty cycle indicates the proportion of time a machine can run without overheating within a set duration. For instance, in a 10-minute cycle, a 60 percent duty cycle allows the machine to run smoothly for 6 minutes, which is 60% of the total time. Factors such as output power and material thickness impact this operational duration. Machines with a duty cycle below 100% need intermittent breaks within 10 minutes, essential for plasma cutters and other electrical tools to prevent overheating. 

4. Assessing the Portability of Plasma Cutters 

Plasma cutters vary in portability depending on size, weight, and design features. Smaller, more compact models are easier to maneuver. Larger and heavier plasma cutters, while powerful, are typically less convenient to move around and are better suited for stationary or more industrial applications where mobility isn’t a primary concern. Some plasma cutters include features like handles or wheels to enhance portability, making them easier to transport from one location to another. Overall, the portability of a plasma cutter depends on its size, weight, and specific design features.  

5. Required Power Specifications for Plasma Cutters 

Plasma cutters have specific power requirements including voltage, amperage, and phase ratings for your outlets. Smaller models commonly use 120 or 240 volts on a single-phase power system, while larger models operate on 3 phase power and may require a breaker rated for 40 amps. Some plasma cutting systems can automatically adapt to different voltages. Reviewing the plasma cutter specifications and documentation to find voltage and amperage. Regular circuit breakers are typically rated for 15 or 20 amps, insufficient for a plasma cutter. Upgrading the circuit or installing a heavy-duty breaker connected to the outlet with a higher amp rating can address this. The latter allows a dedicated circuit for the cutter while enabling other workshop outlets for general use, though it involves additional expense for the new outlet. 

6. Essential Personal Protective Equipment (PPE) for Plasma Cutting 

Eye and face protection

Eye and face protection is vital during plasma cutting to shield your eyes from intense light (UV rays), debris, and sparks. While safety glasses are the minimum recommendation, using a welding helmet or face shield offers superior protection. Choosing the right shade level for the welding helmet according to the plasma cutting current ensures optimal eye protection. 

Clothing made from flame-resistant materials is essential for plasma cutting safety. Wearing long-sleeved, fire-resistant jackets, and pants provides effective protection against sparks and burns. 

Plasma Cutting Current	Welding Hood Shade Level
40 to 60	6
60 to 80	8
80 to 300	8-10

Hand protection

Hand protection is critical; opt for heavy-duty, heat-resistant gloves to shield your hands from burns and sparks. Gloves that balance heat resistance with dexterity aid in maneuverability and protection. 

Respiratory protection

is necessary, especially in confined or indoor spaces during plasma cutting. Use a respirator and ensure proper ventilation to prevent inhaling hazardous fumes or gases, safeguarding your respiratory system from potential harm. 

Ear protection

Ear protection is paramount in environments with excessive noise levels, such as when using a downdraft table during plasma cutting. Utilize properly fitted earplugs, earmuffs, or a combination of both to protect your hearing, especially when sound levels exceed 100 decibels. 

Source	Level
Gas Lawn Mower	80-85dB
Plasma Cutting	100dB+
Rock Concert	110dB+

Text:               Thermacut®
Photo:            Archive of Thermacut, k.s.