Quick answer
The best plasma cutter is one rated to cut the thickness you cut most at a good speed, on power you have. For most shops cutting up to 5/8 inch steel, we recommend the Hypertherm Powermax45 SYNC first. The Miller Spectrum 625 X-TREME is rated for the same 5/8 inch, weighs 21 lb and runs on 120V or 240V. If you cut thicker plate every day, step up to the 65-amp Powermax65 SYNC.
A plasma cutter uses an electric arc and compressed air to cut any conductive metal, including steel, stainless and aluminum, faster and cleaner than an oxy-fuel torch on thin and medium plate. Choosing one comes down to four things: rated cut thickness, input power, air supply, and the consumables you'll buy for as long as you own it.
Rated Cut vs Maximum Cut
Plasma cutter makers publish more than one thickness. The rated (or recommended) cut is the thickness the machine cuts at a practical speed with a good edge. Maximum or sever thickness is higher, but the cut is slow and rough. Size your machine by rated cut for the thickness you cut most, with some headroom.
Hypertherm rates the Powermax45 SYNC to cut 5/8 inch at 20 inches per minute. Miller rates the Spectrum 625 X-TREME for 5/8 inch mild steel at about 15 inches per minute. For heavier plate every day, the 65-amp Powermax65 SYNC is the step up.
Three Plasma Cutters Compared
These are the hand plasma systems we stock. Rated cuts are the manufacturers' figures.
| Plasma cutter | Price | Output | Rated cut | Torch | Stand-out features |
|---|---|---|---|---|---|
| Hypertherm Powermax45 SYNC | $2,196.00 | 45 A | 5/8 in. at 20 ipm | 20 ft hand torch | Single-piece SYNC cartridge; torch sets up the power supply automatically; gouges and marks |
| Miller Spectrum 625 X-TREME | $2,006.40 | 40 A | 5/8 in. mild steel at about 15 ipm | 12 ft XT40 torch | 21 lb, runs on 120–240V (Auto-Line), automatic air regulation, protective X-CASE |
| Hypertherm Powermax65 SYNC | $3,340.00 | 65 A | For daily cutting of thicker plate | 25 ft SmartSYNC torch | Torch reads the cartridge and sets amperage, air pressure and mode; amperage adjusts at the torch |
Input Power and Air Supply
Check your power before you buy. The Miller Spectrum 625 X-TREME's Auto-Line connects to 120–240V single-phase power, and Miller's MVP adapters plug into 120V or 240V receptacles without tools, which makes it the most portable machine here. Expect less cutting capacity on a 120V circuit than on 240V. For the Hypertherm systems, ask us to confirm the input voltage for your shop before ordering.
All three are air plasma cutters, so they need a compressor or shop air supply that meets the machine's flow and pressure specification. Clean, dry air matters: moisture and oil in the air line shorten consumable life and hurt cut quality. The Spectrum 625 X-TREME's automatic air regulation compensates for changes in input pressure.
Consumables and Running Costs
Consumables are the ongoing cost of plasma cutting. Hypertherm's SYNC systems replace the traditional stack of electrode, swirl ring, nozzle and shield with a single-piece cartridge, which removes a common source of operator error, and the Powermax65 SYNC tells you when a cartridge is used up.
For the Powermax45 SYNC hand torch, the 45A Hand Cutting SYNC Consumable Kit ($222.00) includes two drag-cutting cartridges, a gouging cartridge and a FineCutting cartridge.
Hand Cutting or a CNC Table?
Everything above is a hand system. If you plan to connect a plasma cutter to a CNC table, say so before you order: the Powermax45 SYNC is also available in a CPC-port version for machine cutting, and Hypertherm makes a 65A SmartSYNC cartridge for mechanized cutting.
Plasma Cutting Safety
Plasma arcs give off the same kind of radiation as welding arcs. OSHA's minimum for light plasma cutting under 300 amps is shade 8, with shade 9 suggested, where the arc is clearly visible; lighter shades may be used when the workpiece hides the arc. An auto-darkening welding helmet that reaches those shades works for both jobs. See our welding helmet guide for options.
