Plasma Vs. Laser Cutter: Which Is Better?

 

 

August 15th, 2024, Laser Cutting, Plasma Cutting

 

Cutting technologies play a pivotal role in shaping how we design and create. Among the various cutting methods available, plasma cutting and laser cutting stand out as two popular options, offering unique advantages and applications. Whether you're a seasoned fabricator, a small business owner, or a DIY enthusiast, understanding the differences between these two cutting techniques can significantly influence your project. 

 

This blog delves into the intricacies of plasma and laser cutting, exploring their specific use cases, pros, and cons. By examining the strengths and weaknesses of each method, you can understand what option is better suited for your needs. Let’s start with plasma cutting.

 

 

Plasma Cutting

 

Plasma cutting works by using a high-temperature plasma arc to melt and sever conductive materials, typically metals such as steel, aluminum, and copper. The process involves the ionization of gas (usually compressed air) to create a high-velocity jet of plasma that can cut through the material.

 

Plasma Cutting Use Cases

 

Plasma cutting has use across a range of industries. Here are some of the most common uses for plasma cutting:

 

• Metal Fabrication: Metal fabrication is a major part of manufacturing, and is used to create a near endless range of products, whether that be structures, cars, or even art. Plasma cutting is applied during the metal cutting portion of the metal fabrication process. It can quickly and precisely cut brackets, frames, and structural components.
• Automotive Industry: Plasma cutting is often employed for the manufacturing of automotive components such as chassis or vehicle framing, body panels, exhaust systems and more. This industry depends on accurate cuts to ensure that vehicles are able to function effectively while keeping passengers safe. 
• Construction: Plasma cutting is used for cutting steel, beams, girders, and other metal structures and materials that are essential for building frameworks. 
• Aerospace: In the aerospace industry, plasma cutting is used to cut lightweight materials, including aluminum and titanium, for aircraft components. Industries such as aerospace depend on the reliability of plasma cutting to create aircrafts durable enough to withstand varying weight and weather conditions. 
• Home Projects and DIY: Plasma cutting has become a popular option for DIY projects. Homeowners can commission the creation of structural components for furniture, fencing, or gazebos. They may also use it for creating metal art and home decor items. 

 

Plasma Cutting Pros & Cons

 

There are various areas where plasma cutting excels, but like any cutting method, it has some notable limitations. 

 

Pros of Plasma Cutting

 

• Speed: Plasma is incredibly adept at getting metals very hot, very quickly. This means that cutting time is particularly short compared to other methods. 
• Precision: Plasma cutting offers high precision thanks to its ability to produce a very narrow kerf (width of cut). Plasma can make highly detailed cuts and minimize wasted material.
• Versatility: Plasma cutting can be applied to an expansive amount of industries, and cuts a wide range of metal materials such as copper, aluminum, brass, and steel. 
• Clean Cuts: The process produces less slag and dross than other cutting methods, resulting in cleaner edges which often require less post-processing. The high velocity of the plasma jet blows away molten debris before it has a chance to solidify on the cut edges.
• Thickness Capability: With its high concentrated temperature, plasma cutters can efficiently handle a wide range of material thicknesses, from thin sheets to thick plates.

 

Cons of Plasma Cutting

 

• Heat Affected Zone (HAZ): Plasma cutting produces a heat-affected zone that can alter the properties of the metal around the cut. This can potentially impact the material's integrity.
• Limited Material Types: While effective for conductive metals, plasma cutting is not suitable for non-conductive materials, such as plastics or wood.
• Cut Quality: Although plasma provides clean cuts, some other methods may be better options for cut quality. Plasma cutting’s clean cuts may not match that of laser cutting for certain delicate or detailed applications.
• Cutting Limitations: Compared to other methods, plasma has limitations on what types of items can be cut due to its high energy. Plasma primarily cuts plate metal, but industries like Oil and Gas or HVAC will need a method that is able to accurately cut pipes and thin metal sheets. 
• Post-Cutting Treatment: Some cuts may require additional finishing work, such as grinding or sanding, to achieve the desired surface quality, especially for thicker materials.

 

 

Laser Cutting

 

Laser cutting is a manufacturing process that uses a focused beam of high-intensity laser light to cut through various materials with precision. The laser energy melts, burns, or vaporizes the material along a predetermined path, allowing for intricate and detailed designs.

 

Laser Cutting Use Cases

 

• Metal Fabrication: Laser cutting has near endless possibilities for metal fabrication. We wrote an entire blog going into depth on the wide range of unique applications…Read More
• Automotive: Just like plasma, laser cutting is also a popular method for manufacturing prototypes, brackets, and mounts. 
• Construction: Hoppers, lifting beams, feed bins, and chute assembly are some of the areas where laser cutting can be utilized. 
• Oil & Gas: BSG creates tank bases, compressors, and miscellaneous support for pumps for the oil & gas industry. 
• Home Renovation: Homeowners looking for interior and exterior advancements to their home can use laser cutting to create items such as fencing, gates, and window frames.

 

Laser Cutting Pros & Cons

 

Pros of Laser Cutting

 

• High Precision and Accuracy: Laser cutting machines have advanced optics and control systems that allow for fine adjustments in the laser beam's focus and position. This means that cuts can achieve tolerances within 0.1 mm or even less
• Smooth Edges: The focused laser beam melts or vaporizes the material rather than physically cutting it, which causes minimal chipping, burrs, or rough edges. This has the ability to eliminate the need for post-processes. 
• Versatility of Materials: Laser cutting machines can be adapted to cut a wide variety of materials by adjusting the laser wavelength, power, and cutting speed. Machines using a fiber laser, such as Ball Service Group’s laser cutting machine, can cut through a wide array of metals. Alternatively, machines using a Co2 laser can effectively cut acrylic, wood, and paper. 
• Automation and Repeatability: Laser cutting systems often integrate with CNC (Computer Numerical Control) technology, which allows for precise programming of cutting paths. This capability allows for automated production runs with high repeatability, resulting in consistent quality across multiple pieces.
• Less Heat Affected Zone (HAZ): Laser cutting tends to have less thermal distortion or alteration of the material properties near the cut edges, which is crucial for parts that require tight tolerances or specific material characteristics.

 

Cons of Laser Cutting

 

• Limitation with Thick Materials: Laser cutting can handle some thick materials but there caution must be ensured when dealing with thick metals. When cutting thick materials, the energy of the laser may dissipate before penetrating the entire thickness, leading to slower cutting speeds or incomplete cuts. This can require expert-level support to ensure that cuts to thicker materials remain precise and accurate. 
• Safety Considerations: The intense energy of the laser beam presents risks, including burns and eye injuries. Protective measures, such as enclosures and specialized eyewear, are essential to prevent accidents. The process can also produce fumes and particles that require proper ventilation, adding complexity to safety measures.
• Power Consumption: Laser cutting machines, especially those using CO2 lasers, can have substantial power requirements, particularly when cutting through thick or dense materials. The energy consumption not only affects operating costs but may also necessitate upgrades to electrical systems or contribute to higher energy bills.
• Difficulty with Reflective Materials: The reflective nature of certain metals can sometimes reflect the laser beam back into the machine. Laser cutting services will reject certain materials for this reason.

 

 

 

Plasma or Laser Cutting Machine?

 

Both plasma cutting and laser cutting are effective cutting methods which have their own advantages and disadvantages. Their capabilities largely mirror each other, with small differences in how they make cuts and what they can cut efficiently. So with that in mind, how does one decide which is more suitable for a project?

 

When To Use A Plasma Cutting Machine

 

Thanks to its high temperature output, plasma cutting thrives when manufacturing thick materials, such as thick cast iron plates and thick copper plates used in electrical and thermal applications. If your project only includes plates made of metals like brass, iron, copper, stainless steel, aluminum and titanium, plasma cutting will be able to produce cut materials effectively and with a quick turnaround time. If you’re looking for a cost-effective option, plasma cutting machine service tends to run at a smaller price than laser cutting.

 

Utilize BSG’s Top-Notch Plasma Cutting Service

 

At Ball Service Group, we offer precise and efficient plasma cutting services, with the capabilities to handle projects of varying capacity. Whether it’s cutting sheets or thick plates,  or simply a DIY project, BSG can provide the expertise you need to bring your project to life. Request a quote and work with our skilled technicians to optimize your custom metal fabrication project. 

 

When To Use A Laser Cutting Machine

 

Our laser cutting machine at Ball Service Group has a wider range of capabilities than our plasma cutting, making it the better choice for extensive projects that are out of the range of plasma cutting. For example, projects that involve complex shapes, such as tubes, pipes, or other non-flat components, are best executed with laser cutting. Additionally, laser cutting offers an elevated level of precision from plasma cutting, making it the superior choice for projects that involve highly detailed designs. 

 

A High-Power Laser Cutting Machine That Brings Innovation To Everyday Applications

 

Ball Service Group uses the state-of-the-art Amada 9kW ENSIS 3015 RIe to execute laser cutting services across Ontario. This laser cutting machine has extensive automation options to make every cut accurate and consistent. Trust our technicians to handle your projects with exceptional attention-to-detail, ensuring your project comes out exactly the way you pictured it. Contact us today to get started.