The Best Plasma Cutters for Automotive Fabrication

Plasma cutters are used in the automotive fabrication process to cut through various materials such as stainless steel, aluminum or carbon steel. Plasma Cutters are an important part of the process because their speed and precision make it easier to cut through thick metals.

Let's dive into all the different ways plasma cutters are used in automotive fabrication:

1. Custom Parts- Plasma cutters are an ideal choice for cutting custom-shaped parts needed during fabrication. When working on frame parts, bodywork or unique components, plasma cutters allow fabrications to cut metal to a very specific shape and size.
2. Sheet Metal Cutting- When fabricators are working on bodywork, plasma cutters are often used to cut sheet metal for body panels. In the automotive industry there are often rusty or damaged body parts where fabricators will need to create new body panels using plasma cutters to provide the best quality cut.
3. Exhaust System: In order to cut metal pipes and various components for the exhaust system you need to use plasma cutters. This allows for clean cuts that drive performance.
4. Frame Modifications: When working on the frame of a vehicle, plasma cutters are used regularly. This is particularly common when working in the racing industry or with custom-built cars. Consider scenarios where roll cages are being built, structure is being reinforced or you are cutting parts to help reduce overall weight of the vehicle. Plasma cutters are a crucial tool in any of these modifications.
5. Car Restoration: When working with older vehicles, it is important to have a good plasma cutter. They will allow for precise cuts when working with rusted or damaged parts. Anytime you are looking to restore a vehicle's structure, you'll use a plasma cutter to cut edges that can then be welded to new parts.
6. Custom Cut Holes: Plasma cutters are used whenever a custom sized hole needs to be cut to ensure a perfect fit for mounting brackets, lights or other parts that need to be installed. The cut quality in these settings is extremely important.
7. Speed and Efficiency: It's hard to imagine a fabrication world where plasma cutters aren't a key tool for car body repairs. Plasma cutting is significantly faster than traditional cutting methods, like oxy-fuel or using manual saws. Plasma cutters also generate way less heat which ultimately reduces the risk of warping metal. In the automotive space this becomes important because precision is crucial.
8. Detailed Work: When fabricators are in need of precise cuts for intricate work on smaller or more detailed work they will reach for their plasma cutters. When working on suspension components or engine parts, high precision cutting is much needed.
9. Reducing Waste: Because plasma cutters are so accurate, less waste material is created. This makes it a very efficient tool for fabricators. Automotive fabrication typically requires cost control and managing material use is one way to ensure costs stay down.

As you can see, plasma cutters are an indispensable tool in the plasma system, more specifically the automotive applications space. They are capable of cutting through steel, copper, mild steel and other materials used daily in automotive fabrication.

What is the best brand of plasma cutter?

When shopping for plasma cutters you'll want to consider budget, material thickness and the intended use. Another factor to keep in mind is whether you're a professional fabricator or a hobbyist working out of your home shop. The "best" brand for a plasma cutter will vary greatly but we certainly have some favorites among several models.

Everlast

Everlast is a great brand that offers balance when it comes to price and performance. It's an ideal choice for those who need a cost-effective plasma cutter without giving up quality results.

One of our favorite Everlast models is the PowerPlasma 52i . It's a compact but powerful plasma cutter offering the latest IGBT inverter technology. We really enjoy the large, bright digital displays that make it much easier to read, even in brighter conditions. The new blow-back torch design on this unit also includes two pilot arc modes, one for continuous re-lighting and one with a tip saver mode to limit the pilot arc time.

Miller

Another key player in this space is Miller. Known for making reliable and high-quality plasma cutters that will work well in a professional setting or at your home shop. Miller offers many models depending on how much you are looking to spend and the use case.

Hypertherm

This company is oftentimes regarded as the leader in this space. They offer high quality, precision and durability. Their plasma cutters are known for quality and offer flexibility. They are perfect for heavy-duty and industrial spaces. They aren't cheap though and will cost you a pretty penny! The money you spend on this purchase will be well worth it in the long run.

What to look for when buying a plasma cutter?

As with any kind of tool shopping, there are several factors to focus on to ensure you get the best machine, at the best price. Shopping for plasma cutting machines can quickly become overwhelming if you aren't armed with some background knowledge.

We've done the research for you and have identified key factors to consider when exploring the best plasma cutter options.

Amperage

Amperage is important because it determines how thick of a material you can easily cut through. Take some time to consider the materials and thicknesses of those metals you'll be most frequently working with.

Fabricators who plan to cut sheet metal (1/8" to 1/4") will find that a lower amperage machine in the 20-30 amp range will be sufficient. Those working frequently with thicker materials (1/2" or higher) will need a higher amperage machine in the 40-50 amps range.

We recommend choosing a plasma cutting tool with an amperage rating that will work best for your most frequent types of jobs.

Cutting Speed

Cutting speed looks at how fast the plasma cutting machine can get through a specific material. You'll want to also consider the cutting quality since speed is only relevant if the end result is of high quality.

Plasma cutters with higher amperage will cut faster and with a cleaner edge. It's important to find a balance between speed and the resulting quality.

We like to recommend that shoppers closely consider user reviews when browsing products. If you find that not many reviews are left for a product, dive into the product specifications in the owner's manual to learn more on the cut quality and precision.

Portability

If you'll find yourself doing work on the go or needing to transport the plasma cutter between jobs, portability will be an important consideration. Machines that are lightweight and compact make for easier transportation.

There are plasma cutters specifically designed to be portable if this is an important feature for you.

Power Supply

Plasma cutters can be found in dual voltage, either a 110v or 220v power supply. The 220v is going to be the more powerful of the two. If you'll be working mostly in a home shop, a 110v model will likely be what you need to get the job done.

For heavier duty work or industrial type cutting, a 220v model will be preferred because it can handle much thicker metals and provides a higher power output.

Air or Gas

Plasma cutters are either going to use compressed air (air supply) or they will use a gas like nitrogen or oxygen (gas supplied).

We tend to favor the air supplied plasma cutters because of their convenience and ease on the wallet. This is again another situation where you'll need to consider the environment and material you'll be fabricating in. For thicker materials or detailed cuts, you may need to choose a machine that supports these gases.

Ease of Use

Be aware of the brands in the market and know which ones are reputable and reliable. Take time to review the warranty and if you can, talk to some other fabricators for their feedback on the plasma cutter and the warranty. Chances are, they will be able to tell you first hand if they've had to use the warranty, and if so, was the brand reliable and trustworthy?

You likely won't go wrong if choosing a brand like Everlast, Miller, Hypertherm or Lincoln Electric. These are all big players in the field and tend to take good care of their customers.

Budget

You'll notice quickly when browsing plasma cutters that they vary greatly in price depending on different features and quality. Set a budget that is realistic for the amount of use the cutter will get and the type of work you'll be doing.

If you are starting off in the field or looking to fabricate as a hobby, consider a mid-range model that will still perform well but won't break the bank. You can always upgrade to a heavier duty machine in the future.

On the other hand, if you are a professional and will be using this plasma cutter regularly in a heavy-duty environment, don't cut corners. Opt for a high-quality machine and spend a bit more money and it will last for years to come.

Once you've considered these factors, you'll be able to make a smart decision on a plasma cutter that is right for you and your needs.

How precise can a plasma cutter cut?

Plasma cutters are a great option for precision cutting when working with thicker metals specifically. The range of precision will vary and depends on things like the quality of the machine, the material being cut and the thickness of the metal.

What is Kerf?

Kerf refers to the width of the cut that is made. Typically a kerf width between 1/16" to 1/8" is standard. The narrower the kerf, the more precise the cut will be. Higher quality plasma cutters often have a finer kerf which will allow for a more detailed and precise cut.

Kerf is basically the material that is removed during the cutting process and its size can influence the end result and its quality.

What is Tolerance?

Cutting tolerance references the allowed variation in the cut dimensions. Typically plasma cutters can have a tolerance of + or - 0.5mm to 1mm, meaning the cut can vary slightly from the intended measurements.

Now, laser cutting will offer the most precision when cutting but in somecases plasma cutters are accurate enough for fabrication jobs.

What is Cutting Speed?

Seems obvious enough, but cutting speed refers to how quickly the cutter moves on its path. Cutting too fast can reduce the quality of the cut, but cutting too slowly can actually cause too much heat, resulting in warping. It's important to find the right balance between speed and quality.

What is a CNC Plasma Cutting Machine?

Computer Numerical Control plasma cutters are automated systems that use a computer control system software to guide the torch along its path of cutting. CNC plasma cutters are able to get much higher precision because of the system directing it. With a well balanced system, a CNC cutter can expect tolerances as fine as + or - 0.5mm or better in some cases.

Although plasma cutters provide good precision for general fabrication, they are not going to have the ability to be as precise as using laser cutting.

What is the best PSI for a plasma cutter?

PSI stands for "pounds per square inch" and refers to the amount of force applied over one square inch area. It determines the air pressure required to supply to the plasma cutter in order to create a stable plasma arc. Using the proper PSI will ensure efficiency and an end result of smooth and clean cuts.

The ideal PSI for a plasma cutter depends on the model, the material you are cutting and its thickness. Most commonly a cutter will require an air compressor that delivers between 60-120 PSI of air pressure.

PSI is important to consider because if the air pressure produced is too low, the plasma arc may be unstable which will result in poor quality cuts. Exceeding ideal PSI settings can cause high heat which could lead to warping of the metal.

Always check the manufacturer's specifications to ensure ideal performance and safety.

Can a plasma cutter cut a diamond?

Diamonds are very hard to cut because of their hard, crystal structure. On the Mohs scale of hardness, diamonds fall at a 10 which is the highest possible rating.

In short, a plasma cutter is not able to cut a diamond. Its high temperature cutting style is used to melt and blow away materials like metals. A diamond is a very hard material and is not impacted by heat the same way metals are.

Cutting diamonds is work cut out for a special tool like a diamond- tipped or laser cutting tool. These tools are used because they are able to cut through the diamond without causing damage.

What are the 2 different types of plasma cutters available?

There are two main kinds of plasma cutters available on the market- Manual vs. CNC.

Manual

• Controlled by the Operator.
• More skill required to operate and achieve accurate cuts.
• Great for smaller or custom work.
• Higher level of control by the operator.

Computer Numerical Control (CNC)

• Controlled by Automation.
• Higher precision cutting.
• Ideal for mass production or very detailed designs.
• Typically faster and more efficient for larger or repetitive cutting tasks.

Manual plasma cutters are typically used during smaller projects, auto body repairs or hobby work. CNC cutters are commonly used in the industrial setting where there is larger scale fabrication happening. It's often the preferred method for sign-making or metal art.

What kind of maintenance is needed for a plasma cutter?

Like with most equipment, taking proper care of your tool is going to be an important part of the ownership process. Proper maintenance will help keep the cost of repairs down and ensure high performance and safety.

1. Clean your machine regularly.
2. Inspect and replace parts needing it.
3. Maintain the Air Supply.
4. Clean the torch regularly and inspect for wear and tear.
5. Regularly clean the ground clamp.
6. Inspect cables and the power supply often.
7. Keep an eye on the Duty Cycle.
8. Perform functionality tests to help catch any potential issues early.
9. Dedicate a designated storage spot for the machine.
10. Have a set of replacement parts on hand

Conclusion

In conclusion, the best plasma cutters for the automotive fabrication space should offer a balance of power, durability and precision. Companies like Everlast, Miller and Lincoln Electric are top choices in the space and with the proper care the service life of the machine will be long. The right plasma cutter for you will depend on your needs, budget and whether you are just getting started in the space or an experienced professional fabricator. Visit Arc-Zone to explore the right plasma cutter for your needs!