10 Best Plasma Cutter Reviews 2019 and Buying Guide

While you’re looking for a best plasma cutter, Let me explain why it’s a wise decision by you:

Since they use gas to melt (and cut) metals, the plasma cutters do their job five times – yes, FIVE TIMES – faster than their traditional counterparts. Such a gigantic speed enables them to cut up to 500’’ of metal every minute.

The below graph can give you a better insight on the cutting performance of Plasma Cutter on different metals

Need more reasons to make up your mind?

Plasma cutting is the most versatile and safest of all cutting mechanisms.

  • Versatile because it could deal with alloy, steel, iron, brass, aluminium, and stainless steel and other conductive metals without breaking a sweat.
  • Safe because the gas that it employs is inert; whose lack of flammability won’t allow it to become a safety hazard.

Hence the reason why after taking into consideration various factors including cut-rate, maximum cut thickness, input voltage, and duty cycle, we’ve rounded up the ten best out of 55+ cutters reviewed for you.

Best Plasma Cutter 2019 – Top Picks

After hundreds of hour reading the technical specifications and customer feedbacks, we came up with this super ten products. This is a complete reviewed article where you can get everything about a plasma cutter with a Bonus tip.

Bonus? Ahan! It is the Highlighted text after every reviewed product. In this step, where you can make up your mind whether to buy the product or not? So, let’s go.

Lotos LTP5000D 50Amp – Best Plasma Cutter

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Lotos LTP5000D 50Amp
520 Reviews
Lotos LTP5000D 50Amp

  • Weight: 26 pounds
  • Duty Cycle: 60%
  • Input Voltage: 110V/220V
  • Maximum cut thickness: 19mm (¾’’)
  • Warranty: 1-year

Depending on application and material, the Lotos LTP5000D can cut materials from ½’’ to ¾’’. It comes with a 9’5’’ long hose which offers three-pin connections so that you can connect it virtually anywhere. Also, thanks to the included bracket, you can mount this unit to a wall.

The LTP5000D uses pilot arc technology which means it can cut metal without touching the tip. This helps to cut rusty or painted metal. Also, increases longevity.

Equally convenient is the provided air regulator. The easy-to-read gauge of the regulator allows you to monitor pressure readings anywhere between 0 and 150psi. It also has a sturdy handle to assure ease of carrying and a V-MOSFET transistor which generates not only high power but also provides consistent current.

And the best part is the power inverter technology and PWM (Pulse Width Modulation) which possibles smooth and clean cuts.

For cooling, it uses EBM PAPST cooling system. In case you don’t know, ebm-papst is german made and one of the higest selling cooling system in the world.

In terms of extras, you won’t have any complaints about this model. For, it provides a nozzle, group clamp, air hose, four air hose clips, and two air hose connectors. And that’s not all. Its manufacturer offers a 1-year warranty on the model, while also providing tons of free, online tutorials.

Check Out this Video for a Better Insight

What makes the Lotos LTP5000D a truly must-have is its dual-voltage capability. That means you can operate it at both 110v at 50Hz or 220v at 60Hz frequency. Plus the digital inverter technology.
Pros
  • Dual-voltage capability
  • Has a V-MOSFET transistor
  • Pilot Arc (Non-touch) cutting
Cons
  •  Pricey but worthy

Hobart Airforce 500565 27i

Hobart 500565 Airforce 27i
19 Reviews
Hobart 500565 Airforce 27i

  • Weight: 32.1 pounds
  • Duty Cycle: 35%
  • Input Voltage: 120V/240V
  • Maximum cut thickness: 5/8’’
  • Warranty: 1-year

In contrast to the other Hobart model in this review, the 500565 comes with a multi-voltage plug which provides this model with a dual-voltage (120V and 240V) capability. Run it at its maximum power, and this unit offers a maximum cutting thickness of 5/8’’ when dealing with mild steel while the ideal being 3/8’’.

To save power, Hobart has armed this model with an on-demand fan which runs only when dirt or debris are blocking the unit, thereby causing overheating though this fan doesn’t need to turn on often because of the wind tunnel technology of this model.

As a result of this technology, this model draws in air from the outside, thereby protecting the PC board and other components from noxious dirt. Its thermal overload protection, meanwhile, shuts down the unit if the duty cycle exceeds the safe limit, hence preventing machine damage.

Lastly, the Power Factor Correction (PFC) Circuitry is something that draws up to 30% less amperage as compared to other variety in the list with the same cutting range.

Thanks to its XT30R torch, not only do you get a buttery cut but you don’t have to deal with slag as well. Throw into the mix the 12 ft lead of the torch, and you’ve got an incredibly handy product on your hands. 
Pros
  • Multi-voltage plug
  • On-demand fan
  •  XT30R torch
Cons
  • Expensive

ZENY DC Inverter  – Best DIY and Cheapest

ZENY DC
91 Reviews
ZENY DC

  • Weight: 24.4 pounds
  • Duty Cycle: 60%
  • Input Voltage: 110V/220V
  • Maximum Cut Thickness: 15/32 ''
  • Warranty: 30-day

In contrast to most models in this review, the Zeny Cut-50 is a dual-outlet machine – which machines it can operate both via a plug as well as an air hose. Taking its versatility to the next level is the digital readout and you’ll get a massive 85% efficiency from this model.

Furthermore, it offers a cut rating of ¼,’’ and the dual-voltage design of this model allows it to operate at 110V and 220V. Its ‘’supply gas ahead’’ and ‘’turn off gas delayed’’ options, meanwhile, provide a steady input of power to make sure that you get a stable output.

Additionally, the Zeny inverter has a duty cycle of 60% with an amperage range which varies between 20 to 50 amps. The presence of touch-start in this model means you won’t have to exert any physical effort to get it running. And though its weight of 22lb doesn’t make it heavy, the Zeny still comes with a carry handle for portability.

Those who are on strict budget can go for this.

If you don’t know it already, it is the improved cooling method of this plasma cutter which sets it apart. By bringing down the temperature of the cutting torch, it not only makes the whole operation safer but also increases the shelf life of the cutter. 
Pros
  • Improved cooling method
  • Dual-voltage design
  • Lightweight and portable
Cons
  • Length of cable is short

Hypertherm 088079 Powermax30

Hypertherm 088079 Powermax30
30 Reviews
Hypertherm 088079 Powermax30

  • Weight: 21 pounds
  • Duty Cycle: 35% @ 240V
  • Input Voltage: 120V/240V
  • Maximum Cut Thickness: 5/8’’
  • Warranty: Power Supply 3 years & Torches- 1 year

What’s the best thing about the Hypertherm 088079? It automatically adapts to its power source. How? Thanks to its automatic dual-voltage design. Adapters are included in its package, and a 15-foot torch lead keeps you safe by supplying strain relief at both ends. Not to mention it includes inverter type power supply.

The 088079 uses two-in-one technology which means high power cutting for thick metals and fine cutting for thin metals.

Moving on, this model provides 3.8kw of cutting power, which means you can cut most metal type using it. While its recommended cut capacity is of 3/8’’, the manufacturer states that if you’re dealing with mild metals, it can cut 5/8’’ as well. It uses only compressed air which is safe.

Also, since it comes in the form of a set, the packed kit of the Hypertherm provides all the consumables that you might need. Have doubts? Then scour through its accessories. You’ll note that in addition to electrodes and nozzles, the kit contains a retaining cap, shield, and a swirl ring.

Its fastest cutting speed with brilliant cut quality made it unique as it saves the most valuable thing, i.e. time. 

 

Pros
  • Auto voltage technology
  •  Has a comfortable grip
Cons
  • bit expensive

PrimeWeld Premium & Rugged

PRIMEWELD Premium & Rugged 50A Air Inverter
111 Reviews
PRIMEWELD Premium & Rugged 50A Air Inverter

  • Weight: 22 pounds
  • Duty Cycle: 60%
  • Input Voltage: 110V/220V
  • Maximum Cut Thickness: ½’’
  • Usage:
  • Warranty: 3-year

Designed for the professionals by the professionals, the PrimeWeld Premium & Rugged comes in a hard-pack which makes carrying it pretty ease. It has a cut rating of ½’’ – the best of any model in this review – a steady flow of plasma means it can work effortlessly on thin plates too.

The long air cable has a built-in air filter which to supply the machine with clean air. Complementing its cable length is its 65 psi air pressure which makes sure that less effort is required to get the job done.

Lastly, to justify its slightly expensive price tag, this model has packed its kit with useful attachments. Apart from the torch and air regulator, you’ll get two plasma cutter tips, four clamps, two couples and a 12’ ground clamp on opening its hard case. Oh, and the case has a handle too, making it easy to move around.

Though it is obvious, yet, the ½’’ cut rating of this model is what makes it a standout performer. Why? Go through any other model in this review, and you’d be hard-pressed to find one who can rival the PrimeWeld Premium and Rugged in this aspect.
Pros
  • ½’’ cut rating
  • Portable
  • MOSFET transistor
Cons
  • Doesn’t provide a 110v plug in its kit

Hobart 500566 AirForce 40i

Hobart 500566 Airforce 40i
21 Reviews
Hobart 500566 Airforce 40i

  • Weight: 34.3 pounds
  • Duty Cycle: 50%
  • Input Voltage: 220/230/240V
  • Maximum Cut Thickness: 7/8’’
  • Warranty: 1-year

Does your job involve cutting mild steel? Then you need the Hobart 500566 AirForce. With a cut rating of 5/8’’ mild steel, this 40amp plasma cutter enables you to cut through steel, stainless steel, copper and a bevy of other metals.

Next comes the fan-on-demand technology (same as Hobart 500565 )of the AirForce, which reduces power consumption by running when needed. Equally versatile is its WindTunnel technology which protects the unit from dirt by drawing internal air.

What’s more, thanks to its thermal overload protection, the unit automatically shuts down when facing blocked air flow or limit-crossing duty cycle. You also get a Post-Flow Cooling System which brings down its temperature the moment you cut, thereby increasing the shelf life of its electrodes and tips.

To cut you coated or painted surfaces – as well as perforated/expanded metals – this unit,  comes with a pilot arc controller. It cuts through all such substances and that too without retriggering the torch. Many users quoted this as its best feature. So, you can go for this if the same is your case.
Pros
  • Produces less slag
  •  Less power consumption
Cons
  • No digital display

AHP AlphaCut 60

AHP AlphaCut 60 Amp
22 Reviews
AHP AlphaCut 60 Amp

  • Weight: 47.4 pounds
  • Duty Cycle: 60%
  • Input Voltage: 110V/220V
  • Maximum Cut Thickness: ½.’’
  • Warranty: 3-year

Even though this model is on the lighter side, its compactness hasn’t stopped its manufacturer from packing its console with easy-to-read warning lights, air pressure indicator and analog dials. That means you won’t get any high-end controls or digital display from this plasma cutter.

Turning our attention to its cutting capabilities, and the machine provides two options. Plug it into a 110v power outlet, and it would smoothly go through up to 1/8’’ mild steel. Conversely, if you hate struggles, find a 220v outlet and the AlphaCut 60 would cut up to 3/8’’ steel. As compared to competitor models Its iPT torch coupled with the unit’s design favors the use of lower CFM air compressors.

Lastly, The presence of a pilot arc and blowback start to complement each other in making the startup and running of this plasma cutter as smooth as possible.

The feature of this model which impressed us the most was its duty cycle. While most cutters stop short at 40% to 50% cycles, you could get maximum power from the AlphaCut even at 60%. In simple parlance, if need your work to be done for a longer period then go for this.
Pros
  • The duty cycle of 60%
  • Huge cut rating
  • Dual voltage supply
  • 3-year warranty
Cons
  • Performance on 110v is subpar

Hypertherm Powermax 65

Hypertherm Powermax 65
7 Reviews
Hypertherm Powermax 65

  • Weight: 64 pounds
  • Duty Cycle: 50%
  • Input Voltage: 200 – 480 V, 1-PH, 50/60 Hz and 200 – 600 V, 3-PH, 50/60 Hz
  • Maximum Cut Thickness: 1’’
  • Warranty: 3-year

A brief comparison of the Powermax 65 with other models in this review makes it crystal clear that this cutter has a high-end price. Fortunately for it, its features do well to justify the price tag. Take, for instance, its ability to cut through 1/2’’ stainless steel @ 32’’/minute.

If you’re rutting it on 240volts, the 65-amp cutter provides a decent duty cycle of 50% – which is plenty of runtimes even in heavy-duty applications. Provided you’re looking for precision cuts, and you can do so by setting it up with proper tips and torch.

It also lets you set it up for a wide range of tasks including pipe cutting, X-Y table cutting, mechanized and robotic cutting, and more. And to make sure that its consumables last long, this model lets you use 7 different torch configurations as well.

One feature of the Powermax 65 which most other plasma cutters on the market cannot even come close to is its 1’’ cut rating. Throw into the mix, its speed of cutting through 32’’ of stainless steel per minute, and this device becomes a must-have for heavy duty applications. 
Pros
  •  Industrial-grade cutter
  •  Excessively powerful
  •  Makes sure consumables last long
Cons
  •  Heavy

Miller Spectrum 625 X

Miller Spectrum 625 X-treme
5 Reviews
Miller Spectrum 625 X-treme

  • Weight: 21 pounds
  • Duty Cycle: 50%
  • Input Voltage: 120V/240V
  • Maximum Cut Thickness: 5/8''
  • Warranty: 3-year

For a plasma cutter which could slice through materials of up to 0.6’’ thick, the 625X has an ergonomically designed handle to provide a comfortable grip. It has an auto-refiring pilot arc which automatically switches in/out when dealing with expanded metal, which means there you don’t need to manually re-trigger it.

In addition to its fan-on-demand – which runs only when the temperature of the unit exceeds a preset safe value – this plasma cutter has automatic air regulation which compensates for input pressure variation to provide consistent torch pressure which gives the perfection in cutting.

Furthermore, to provide ultimate flexibility, its auto-line circuitry automatically connects to a single phase, 120-240V AC power. It also has multi-voltage plug adapters which allow you to connect the unit to 120 or 240V spectacles without using any tools.

As stated earlier, the Miller Spectrum 625X comes with an auto-refire technology. Not only does it automatically turn on/off the pilot arc, but the auto-refire technology – after taking into consideration the thickness of metal at hand – provides maximum power for uniform cutting.
Pros
  • Ultra-portable
  • No-slip grip and ergonomic handle
Cons
  • Size of the case is small

Lotos LT5000D 50Amps

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Lotos LT5000D
372 Reviews
Lotos LT5000D

  • Weight: 5 lbs
  • Duty Cycle: 60%
  • Input Voltage: 110V/220V
  • Maximum Cut Thickness: ¾’’
  • Warranty: 1-year

First things first, the LT5000D is a dual-voltage plasma cutter which comes with a digital display. It operates via an air compressor, and this unit is less of a safety hazard than its oxy-fuel counterparts. Having a custom-fit torch means you can set it to either finger or thumb positions. Add to the mix its low-profile touch head, and you can even use this cutter in tight spaces. The installation type is pretty similar to tig welding type.

Increasing the utility of this model is its high-end MOSFET transistors which are known for providing steady and high power output.

Want more features? The LT5000D obliges with its advanced German cooling system which reduces its internal temperature to increase the model’s shelf life.

German Cooling System is the only extra feature that is missed in the Lotos LTP5000D model

Having an equally good effect on the model’s longevity, the pre-installed air filter regulator adds a similar effect on the model’s durability.

Lastly, the presence of Pulse-Width-Modulation technology provides this model with three benefits. While it reduces the weight and dimensions of the main transformer on one end, the technology reduces the running costs by increasing the cutter’s efficiency by 30%, on the other.

If you want a budget alternative of Lotos LTP5000D, this one is for you. It costs almost half.

Where to start? Apart from having an advanced cooling system – which increases the durability of this model, it has a Pulse-Width-Modulation technology which increases the efficiency of this model by 30% and reduces the running costs.
Pros
  • Above-par cut rating
Cons
  • Consumables are expensive to replace

How to Choose The Right One?

Following are the factors you need to consider while choosing a plasma cutter:

Type of Plasma Cutting

On which surface are you going to use the cutter: table or floor? If you are unsure about the future, get a plasma cutter which offers both. That’s right; there are cutters out there who let you switch between handheld and mechanized modes, and back again.

Or, if you can afford to spend extra, there’s nothing better than a CNC plasma cutter. They rely on a computer to control the path of the torch, with the term CNC referring to “Computer Numerical Control.” And the best part about them? They provide accuracy and quality for all types of metal fabrication.

Cut Rating

The cut rating determines the cutting speed of a plasma cutter w.r.t. The thickness of the metal it is dealing with. At the cost of over-generalization – since most manufacturers have their names for cut ratings – here are the three most common cut ratings out there:

  • Rated Cut:

Cuts mild metal has a cutting speed of 10 inches per minute.

  • Quality Cut:

Cuts thicker materials and has a lower cutting speed.

  • Sever Cut:

Can cut through the thickest of metals, though the cutting speed is less.

Pilot Arc vs High-Frequency Plasma Cutters

Once you’ve chosen between a handheld and CNC plasma cutter, the next stage involves choosing between these two.

  • Pilot Arc

Pilot arc operate on the principle that your interfere with electronics should be as less as possible when the cutter is doing its job. Unlike high-frequency plasma cutters, they do not undergo a scratch start – which is the reason why they last longer. Finally, they have ridiculously low running costs.

  • High-Frequency 

Go to your nearby fabrication shop, and 9/10 times you’ll come across a high-frequency plasma cutter. In addition to being cheaper – hence the reason why they are so ubiquitous – the high-frequency cutters produce a stable cutting arc. Since they undergo a scratch start, these cutters have a lower shelf life.

Other features

Regardless of your project type, you must look for these features before making a purchase:

  • Duty Cycle

Want to meet output quotas? Have a huge order to fulfil? Then get a plasma cutter with a high duty cycle – which determines the time your cutter can run continuously without requiring a shutdown. Put, if your cutter’s duty rating is 50%, it might only operate for 5 minutes out of 19 minutes total.

  • Cut Quality

Looking for the cleanest cuts out there? One way to make sure of that is getting a cutter which offers continuous plasma arc. By cutting in a non-disrupted way, it provides a uniform and clean cutting quality. Also, if you can, get MOSFET transistors in your machine as they also help to create a steady arc.

Conclusion

Read the above mentioned reviews carefully? If your answer to the question isn’t in the affirmative – which means you need our recommendation – our vote goes in favor of the  Lotos LTP5000D 50Amp. Though slightly expensive, this plasma cutter packs a brilliant bunch by offering a market-high duty cycle, excellent cut thickness, and uniform cut quality. Add to this its warranty of 1-year, and this plasma cutter becomes a must-have.

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