The Best Plasma Cutters For All Welding Needs

Plasma cutter

The Best Plasma Cutters For All Welding Needs

Are you in search of the best plasma cutter to suit your cutting needs? Look no further! In this comprehensive review, we will explore the top 9 best plasma cutters currently available in the market. 

Whether you’re a professional welder or a DIY enthusiast, these plasma cutters are guaranteed to deliver precise and efficient cuts. 

Keep reading to find the perfect plasma cutter for your projects.

Overall Best

Hypertherm Powermax45 XP Hand System w/o CPC – 20′ Leads Plasma Cutter

  • The lightweight design and portability make it a convenient choice for both on-site and workshop use.
  • It features Hypertherm’s patented Duramax torch technology for enhanced durability and ease of use.

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Second Best Plasma Cutter

Miller Electric Plasma Cutter, Spectrum 625, 90PSI, 20ft

  • The X-Treme version of this plasma cutter offers improved durability and weather resistance. This makes it suitable for outdoor use.
  • The Auto-Line technology allows for automatic voltage adjustments.

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A Quick Comparison of the 9 Best Plasma Cutters

1. Hypertherm Powermax45 XP Hand System w/o CPC – 20′ Leads Plasma Cutter [Overall Best Plasma Cutter]

2. Miller Electric Plasma Cutter, Spectrum 625, 90PSI, 20ft [Second Best Plasma Cutter]

3. Lotos LTP5000D Plasma Cutter, 50 Amp Non-Touch Pilot Arc Plasma Cutter Machine, Dual Voltage 110/120V or 220/240V, ½ inch Clean Cut and ¾ inch Severance Cut, Brown [Best Plasma Cutter For Thick Metals]

4. Hypertherm Powermax 65 SYNC Plasma Cutter w/ 25 ft. 75-Degree Handheld Torch 083343 [Best Plasma Cutter For Heavy-Duty Cutting Applications]

5. Hobart AirForce 40i Plasma Cutter, Model:500576 [Best Plasma Cutter For Beginners]

6. Everlast PowerPlasma 62i 60 Amp CNC Compatible Plasma Cutter [Best Plasma Cutter For Versatility]

7. Lincoln Electric Tomahawk® 375 AIR Plasma Cutter with 10 ft (3.0 m) Hand Torch [Best Plasma Cutter For Reasonable Price]

8. ESAB Cutmaster 60i Plasma Cutter [Best Plasma Cutter For Reliable Cutting Performance]

9. Hypertherm Powermax 85 SYNC Plasma Cutter w/ 50 ft. Handheld Torch 087184 [Best Plasma Cutter For Lightweight And Portability]


All You Need To Know About The Top 9 Best Plasma Cutters for Precise and Efficient Cuts

Below are the top 9 Best Plasma Cutters and all you should know about them:

1. Hypertherm Powermax45 XP Hand System w/o CPC – 20′ Leads Plasma Cutter

Brand

Hypertherm

Durability

It features Hypertherm’s patented Duramax torch technology for enhanced durability and ease of use.

Amperage

45 Amps.

Duty Cycle

50% duty cycle.

Size

17.4 x 6.8 x 14.1 inches.

Weight

36 pounds.

The Hypertherm Powermax 45 XP is a top-rated plasma cutter known for its exceptional cutting performance and reliability.

With a cutting capacity of up to 1/2″ thick materials, this model is suitable for a wide range of applications. 

Its fast cutting speeds, clean and precise cuts, and excellent arc stability make it a favorite among professionals. 

Moreover, its lightweight design and portability allow for easy on-site and workshop use. With a 50% duty cycle at 45A, the Powermax 45 XP ensures extended cutting periods without compromising performance. 

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2. Miller Electric Plasma Cutter, Spectrum 625, 90PSI, 20ft

Brand

Miller Electric

Durability

The X-Treme version offers improved durability and weather resistance, making it suitable for outdoor use.

Amperage

45 Amps.

Duty Cycle

50% duty cycle.

Size

‎31 x 11.5 x 15 inches.

Weight

40 pounds.

The Miller Spectrum 625 X-Treme is a compact and powerful plasma cutter designed for versatility and performance. 

With a cutting capacity of 5/8″ thick materials, it can handle a wide range of cutting tasks. 

One standout feature of this model is its Auto-Line technology, which automatically adjusts voltage to ensure consistent and reliable cutting performance, even with fluctuating power inputs. 

Furthermore, its lightweight construction, carrying handle, and convenient shoulder strap make it highly portable.

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3. Lotos LTP5000D Plasma Cutter, 50 Amp Non-Touch Pilot Arc Plasma Cutter Machine, Dual Voltage 110/120V or 220/240V, ½ inch Clean Cut and ¾ inch Severance Cut, Brown

Brand

Lotos Technology

Durability

Its dual voltage capability (110V/220V) adds versatility and convenience to this plasma cutter.

Amperage

50 Amps.

Duty Cycle

60% duty cycle.

Size

15 x 6 x 12 inches.

Weight

19.4 pounds.

If you’re on a budget but still need a reliable plasma cutter, the Lotos LTP5000D is an excellent choice. 

This budget-friendly model doesn’t compromise performance. 

It effortlessly cuts through various materials up to 1/2″ thick making it suitable for hobbyists, DIYers, and light industrial use. 

With a 60% duty cycle at 50A, it provides consistent cutting power for extended periods. 

The LTP5000D’s compact and lightweight design, along with the included handle, allows for easy transportation and maneuverability. 

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4. Hypertherm Powermax 65 SYNC Plasma Cutter w/ 25 ft. 75-Degree Handheld Torch 083343

Brand

Hypertherm

Durability

It features an automated system process set-up via advanced RFID-enabled SmartSYNC torches and a revolutionary single-piece cartridge consumable that provides trackable utilization data.

Amperage

50 Amps.

Duty Cycle

60% duty cycle.

Size

17 x 6 x 13 inches

Weight

About 40 pounds.

The Hypertherm Powermax 65 is a high-performance plasma cutter for heavy-duty cutting applications. 

With an impressive cutting capacity of 3/4″ thick materials, it can tackle demanding projects with ease. 

The Powermax 65 features Hypertherm’s Smart Sense technology, which automatically adjusts gas pressure for optimal performance and consumable life. 

It is dual-angle design and vented system ensure excellent heat dissipation, prolonging the life of internal components. 

Although relatively heavier than other models, its cutting power and versatility make it a popular choice for industrial and professional use.

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5. Hobart AirForce 40i Plasma Cutter, Model:500576

Brand

Hobart Welding Products

Durability

Its XT40R torch- is designed for increased comfort with ergonomic trigger safety. This provides more efficient cooling and economical replacement cutting tips.

Amperage

40 Amps.

Duty Cycle

60% duty cycle.

Size

23.3 x 10.1 x 12.3 inches.

Weight

21 pounds.

The Hobart Airforce 40i is a reliable and compact plasma cutter suitable for both professionals and DIY enthusiasts.

It comes with a fan-on-demand cooling system that operates only when needed. This reduces power consumption and contaminants drawn into the machine.

The post-flow cooling circuit extends the life of consumables and torches by cooling them with post-flow air after the trigger is released.

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6. Everlast PowerPlasma 62i 60 Amp CNC Compatible Plasma Cutter

Brand

Everlast Power Equipment

Durability

It offers an adjustable post-flow timer with a digital display for maximum consumable life and ease of use.

Amperage

60 Amps.

Duty Cycle

60% duty cycle.

Size

Weight

30 kg.

The Everlast PowerPlasma 60S is a robust plasma cutter that offers impressive cutting power and versatility. 

It can handle heavy-duty applications with a cutting capacity of up to 1″ thick materials. 

The PowerPlasma 60S utilizes inverter technology to deliver precise and clean cuts with minimal distortion. 

It features a 60% duty cycle at 60A, ensuring extended cutting periods. 

The machine’s compact design along with its lightweight construction makes it portable and suitable for both workshop and on-site use. 

The built-in air pressure regulator and moisture separator add convenience and enhance the longevity of consumables.

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7. Lincoln Electric Tomahawk® 375 AIR Plasma Cutter with 10 ft (3.0 m) Hand Torch

Brand

Lincoln Electric

Durability

This machine’s front panel purge control makes it easy to set the airflow rate without initiating the plasma arc.

Amperage

50 Amps.

Duty Cycle

60% duty cycle.

Size

Weight

40 pounds.

The Lincoln Electric Tomahawk 375 is a reliable and versatile plasma cutter designed for both industrial and on-the-go applications. 

It provides efficient and clean cuts with a cutting capacity of up to 3/8″ thick materials.

The Tomahawk 375 employs Lincoln Electric’s proprietary Wind Tunnel Technology which prevents abrasive dust and particles from entering the internal components. This extends the life of consumables. 

The machine’s lightweight and compact design makes it portable and suitable for various job sites. 

Additionally, the front panel purge control allows for easy gas adjustments and fine-tuning.

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8. ESAB Cutmaster 60i Plasma Cutter

Brand

ESAB

Durability

It offers a 7.6 kW rated output 50% Duty Cycle at 60A built for portability and durability with the integral multi-handle design.

Amperage

60 Amps.

Duty Cycle

50% @ 60 A

60% @ 50 A

100% @ 40 A

Size

536 x 199 x 359 mm.

Weight

16.2 kg.

The ESAB Cutmaster 60i is a high-performance plasma cutter that excels in both precision cutting and heavy-duty applications. 

It offers exceptional versatility with a cutting capacity of up to 1-1/2″ thick materials. 

The Cutmaster 60i utilizes ESAB’s True Series Technology. This ensures consistent and reliable cutting performance. 

Its lightweight and compact design coupled with the machine’s handle and shoulder strap enables easy portability and maneuverability. 

Additionally, the automatic multi-voltage detection allows for hassle-free setup. This makes it a user-friendly plasma cutter for professionals.

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9. Hypertherm Powermax 85 SYNC Plasma Cutter w/ 50 ft. Handheld Torch 087184

Brand

Hypertherm

Durability

The machine’s simplified system operation minimizes the time and costs spent on training and troubleshooting.

Amperage

85 Amps.

Duty Cycle

60% duty cycle.

Size

17 x 6 x 13 inches

Weight

About 40 pounds.

The Hypertherm Powermax 85 is a top-of-the-line plasma cutter renowned for its exceptional cutting power and efficiency. 

It handles demanding industrial applications with ease with a cutting capacity of up to 1-1/2″ thick materials. 

The Powermax 85 features Hypertherm’s Smart Sense technology automatically adjusting gas pressure for optimal performance and consumable life. 

Its advanced torch design provides improved cooling, reducing downtime and increasing productivity. 

Despite its heavy-duty capabilities the Powermax 85 remains relatively lightweight and portable. This makes it suitable for various job sites.

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Buyer’s Guide For The Best Plasma Cutters

When it comes to selecting the best plasma cutter for your needs, there are several important factors to consider. Here are some key points to keep in mind:

Cutting Capacity and Power

The cutting capacity and power of a plasma cutter are crucial factors to consider. 

You need to determine the thickness of the material you’ll be cutting regularly and ensure that the plasma cutter you choose has sufficient power to handle it. 

Look for models that offer a wide range of cutting capacities to accommodate different materials and thicknesses.

Duty Cycle

The duty cycle refers to the amount of time a plasma cutter can operate continuously before it needs to cool down. 

It’s an important consideration, especially if you’ll be using the cutter for extended periods.

A higher duty cycle means you can work for longer durations without interruptions. 

Look for a plasma cutter with a duty cycle of at least 40% or higher for optimal performance.

Portability and Size

Consider the portability and size of the plasma cutter. This is important especially if you’ll be moving it around frequently or working in different locations.

Compact and lightweight models are easier to transport and store. However, ensure that the size and weight don’t compromise the cutting capacity or power you require.

Cutting Speed and Precision

The cutting speed and precision of a plasma cutter can significantly impact your productivity and the quality of your cuts. 

Look for models that offer fast cutting speeds without compromising accuracy. 

Some plasma cutters come with features like CNC compatibility and pilot arc technology. This enhances cutting precision and makes complex cuts easier to accomplish.

Ease of Use and Controls

Consider the user-friendliness of the plasma cutter and the ease of accessing and controlling its features. 

Intuitive controls and a clear display make it easier to set up and operate the machine. 

Look for models with adjustable settings and clear indicators for current, voltage, and other parameters, as these features allow you to fine-tune the cutter to your specific requirements.

Consumables and Maintenance

Plasma cutters require consumables such as electrodes and nozzles, which wear out over time and need to be replaced. 

Before purchasing a plasma cutter, check the availability and cost of these consumables.

Additionally, consider the maintenance requirements of the machine and whether it requires specialized servicing or if you can handle regular maintenance tasks yourself.

Safety Features

Safety should be a top priority when working with any power tool, including plasma cutters.

Look for models that offer safety features such as thermal overload protection, voltage fluctuation protection, and a reliable ground clamp. 

It’s also important to ensure that the plasma cutter is properly certified and meets relevant safety standards.

Budget

Finally, consider your budget when selecting a plasma cutter. 

Determine how much you’re willing to spend and look for models that offer the best combination of features, quality, and value within your price range. 

Keep in mind that investing in a higher-quality plasma cutter may save you money in the long run by providing better performance and durability.

You’ll be able to choose the best plasma cutter that meets your requirements and helps you achieve excellent cutting results by considering these factors and evaluating your specific needs. Remember to read reviews and compare different models to make an informed decision.


Conclusion

Investing in a high-quality plasma cutter is paramount when it comes to precise and efficient metal cutting.

The top 9 plasma cutters reviewed here offer a range of options suitable for different applications and budgets. 

A careful review reveals that the Hypertherm Powermax45 XP Hand System w/o CPC – 20′ Leads Plasma Cutter is the best plasma cutter in the market right now. 

Picture of Jeremiah Lambert

Jeremiah Lambert

A certified welder with almost a decade of experience in MIG, Flux, Arc, TIG welding, and metal forgery. Welding certificate course graduate with excellence. Also familiar with and enthusiastic about real estate and home improvement.