Laser Cutting vs. Plasma Cutting
There are many factors which determine the metal cutting process to be used in fabrication projects such as, budget, timeline, costs, production rates, precision levels, and methods of configuring parts. In this regard, laser cutting and plasma cutting stand out as effective solutions for a range of industries. Laser cutting is a process that uses a highly concentrated, intense pulsed or continuous beam of light to cut various metals while plasma cutting uses a melting technique to deliver precise work (e.g., water tanks). So, what are the considerations to be kept in mind when choosing the best cutting method? We will look to dive deeper into this topic.
Overview of Laser and Plasma Cutting
Laser cutting utilizes laser optics and the use of computer numerical control (CNC) to heat and melt the metal while partially vaporizing it. It creates pristine, accurate cuts and works with a range of metals. This technique is often used for various industrial manufacturing applications such as manufacturing pressure vessels, as well as for engraving details, creating intricate notches, and cutting small shapes. Laser cutting is especially useful in cases when the products require precision, whether it is a complex or simple part. Advantages of laser cutting include cutting a wider variety of metals, having a standard tolerance of +/- 0.005″ and being equipped to cut thinner, more intricate metals.
In Plasma cutting, ionized gas, also known as plasma, melts the metal and then expels it. Essentially, compressed air and inert gasses like nitrogen and hydrogen shoot through a nozzle at extreme speeds to essentially blast metals such as stainless steel, copper, aluminum, steel, brass, and others with plasma. This cutting process supports applications like automotive repair, industrial construction, and hopper and tank fabrication, among others.
Choosing the Right Cutting Method
Working with a plasma cutting machine vs. a laser cutting machine can produce different solutions depending on many factors, two of which are the type and thickness of the metal. Some considerations involved when choosing the best cutting method are as follows: –
- Cut edge quality: The quality of a part’s cut edge refers to the squareness of a product’s finished borders. Laser cutting creates a square cut while plasma cutting results in a lower edge quality level, as it is beveled.
- Cut part precision: This precision depends on many aspects, such as heat distortion and the kerf width, as well as the size of the part vs. its programmed size. Laser cutting creates better part precision compared to the plasma technique, hence it adds value as part of custom metal fabrication techniques.
- Cost: The cost of laser vs. plasma metal cutting takes factors such as power, abrasives, gases, consumables, and maintenance into consideration. While plasma cutting is often more cost-effective, the laser technique is faster if thick metals are not being used.
- Production rate: The time taken to cut the metal should also be considered. Plasma cutting will be more efficient with thicker metals, while the laser method is faster and more precise with thinner resources.
- Metal thickness: Laser cutters can cut metals up to 1 inch thick, while plasma can cut up to 5 inches or more.
The Verdict
Laser cutting is a superior option to plasma cutting when direct comparisons are made regarding precision, flexibility, production, edge quality and metal thickness. Understanding how a plasma cutting machine works compared to the laser technique indicates that the latter can help produce products with better precision and quality irrespective of the type of metal. Though laser cutting can be more expensive, it provides a lot of freedom to businesses and is the preferred cutting method of industries!