What is the plasma cutting process?

The metalworking and manufacturing industries have greatly benefited from plasma-cutting technology’s speed, efficiency, and versatility. A CNC plasma cutter epitomizes this advancement, integrating computer numerical control with plasma to cut through various materials with great precision and efficiency. This blog post aims to explain the plasma cutting process in broad strokes, much like a guide, and examine CNC plasma cutters: how they work, their leading parts, and what makes them essential for contemporary fabrication. Whether you have been in the field for a long or are just starting, this article will enable you to comprehend the hows and whys of plasma cutting and its place in modern fabrication.

What is plasma cutting, and how does it work?

Plasma cutting is a thermal cutting procedure that employs a plasma jet of energized gas flowing at high velocities to cut through conductive materials such as steel, aluminum, and copper. The process begins with forming an electric arc between the electrode and workpiece, transforming gas into plasma by raising its temperature to extreme levels. This plasma jet is capable of melting the material at the cutting point. Simultaneously, the high–pressure gas blows away the molten metal, resulting in a clean and precise cut. Plasma cutting is appreciated for its speed, accuracy, and versatility in the thickness of materials, and it facilitates the fabrication process.

Understanding the state of matter: What is plasma?

Plasma is the 4th state of matter, with solids, liquids, and gases. A plasma is created when a particular atom is so heated up or brought under strong electromagnetic forces that its atoms become ionized. Ionization is when atoms lose electrons and form a combination of free and positively charged ions. That ionization state gives plasma unique features, such as the ability to conduct electricity and respond to magnetic forces. Plasma can be found in nature through lightning, the sun, and manufactured products like plasma TVs and neon lights.

The basics of plasma arc cutting

This cutting technique is called Plasma Arc, and it entails using an electrode and gas, especially air, which is subjected to electric current to create an arch, resulting in a high temperature and high-speed jet of ionized plasma. This gas jet can shave through electrically conductive materials. The technique itself fuels the electrode and workpiece with a steady electric current that gives birth to an arch, which, in turn, heats the gas to the point that it engenders plasma. The burning plasma appears to be melting the material, but what is occurring is that the ionized gas is powered at a high speed and blows out the molten metal while simultaneously shaping the cut.

The technical specifics of the Plasma Arc are:

Cutting Current: This is usually between 20A and 400A, concerning the material’s thickness and type.

Gas Type: Depending on the material and air, air, oxygen, nitrogen, or argon may be used.

Cutting Speed: This varies depending on the material type and thickness. For instance, mild steel with a thickness of 1/4 inch will have a cutting rate of 50-60 IPM.

Pierce Capability: Usually, this is beneath or equal to the machine’s maximum cutting thickness, defining the maximum thickness at which the system can pierce cleanly.

Plasma Arc Voltage: This usually operates at 100 to 200V to maintain the cutting plasma arc.

These parameters must be controlled precisely to achieve optimal performance while ensuring high-quality cuts with minimal waste.

Components of a plasma cutter: From electrode to plasma torch

A plasma cutter comprises several critical components that enable efficient and precise cutting. Below is an overview of the key parts and their functions:

• Electrode: The electrode acts as the negative terminal in the plasma arc circuit. Typically made from copper or silver, it contains hafnium or tungsten inserts, which are highly heat-resistant. This ensures the durability and efficiency of the arc generation process.
• Nozzle: The nozzle focuses the plasma arc, creating a narrow, concentrated plasma jet for precise cutting. It is made of copper to withstand high heat and operational wear. The nozzle diameter and design significantly influence cut quality and thickness capability.
• Plasma Gas Supply: This system provides the gas required to produce the plasma arc. Common gases include compressed air, oxygen, and argon-hydrogen mixtures, selected based on the material being cut and desired results. For example, oxygen is often used for mild steel, while argon-hydrogen is preferred for cutting stainless steel and aluminum.
• Shield Cap: Positioned around the nozzle, the shield cap protects the torch components from molten material while ensuring the plasma cutter remains efficient during operation.
• Cooling System: Plasma cutting generates significant heat, and many systems incorporate air or liquid cooling to maintain torch and consumable stability.
• Power Supply: The power unit generates the DC voltage necessary to sustain the plasma arc. Most plasma cutters operate within the 200–400 volts range for industrial applications, while smaller units may require lower voltage levels.
• Plasma Torch: The plasma torch is the interface that delivers the arc to the material. Its lightweight design allows for better maneuverability and precision. The torch houses the electrode, nozzle, and shielding components, all working in unison to ensure accurate cutting.

These components interact seamlessly to produce a plasma arc capable of cutting through various materials with remarkable speed and precision. Proper maintenance of each part is essential for achieving high-quality results and extending the system’s lifespan.

What are the advantages and disadvantages of plasma cutting?

Plasma cutting is popular in several industries due to its many advantages. It is exceedingly effective and works exceptionally well on many metals, including steel, aluminum, and stainless steel. Additionally, this process creates minimal ‘heat-affected’ zones, ensuring no material warping. Lastly, plasma cutters allow for exquisite cuts on thin and thick materials. With some training, anyone can quickly learn to operate these machines.

On the downside, safety measures must be taken when using plasma cutters because they are noisy and produce a lot of fumes. The ventilators needed consume many resources, making the entire process expensive. Lastly, while plasma cutters are phenomenal for cutting metal, they are not very good at cutting nonconductive materials such as wood or plastic.

Benefits of using plasma for metal cutting

Plasma cutting is frequently chosen due to its advantages in industries that require metal cutting. To begin with, there is remarkable speed and precision while cutting thin to medium-thick metals. Depending on the material and equipment, the speed can go up to 500 inches per minute. Secondly, narrow kerf widths are produced, reducing material waste while ensuring high-quality edges that require little post-cut processing. Plasma cutting is also efficient and versatile since a wide range of conductive metals can be plasma cut; industrial systems can cut steel, aluminum, and copper over 2 inches thick with a plasma cutter.

This technology also allows for the integration of CNC, further improving the ability to cut complex shapes accurately. Additionally, compared to oxy-fuel cutting, plasma cutters require preheating, significantly enhancing workflow. Modern plasma cutters are more energy efficient and easier to operate due to advancements in inverter technology. There is also a reduced learning curve for users since these plasma cutters are easier to use. Their practicality and appeal are further increased since they are portable and can operate in various environments, including underwater cutting.

Limitations and drawbacks of the plasma cutting process

Despite their efficacy and adaptability, plasma cutters have certain disadvantages and limitations. One issue is the increased price of plasma systems compared to oxy-fuel cutting or other methods. The precision tools, electrodes, and nozzles are expensive, and the equipment investments are significant in facilitating high-precision work. Also, plasma cutting typically needs a clean and dry compressed air supply or certain gas mixtures, adding expense and complication to operations.

Another drawback is the maximum cutting thickness. Although plasma cutters are effective in cutting up to 2-3 inches deeper than that range, they are mastered by competing processes, such as oxy-fuel cutting, which appear to have more power when handling heavy metals. Theoretically, plasma cutting systems work best in a one-fourth or half-inch range of steels and nonferrous metals such as aluminum or stainless steel.

Regardless of other considerations, precision is also critical. While most modern plasma cutters produce incredible cut quality, they often have issues maintaining tight tolerances with more delicate designs and thinner materials that are susceptible to warping due to heat compared to laser cutting. Furthermore, plasma cutting creates a lot of heat and sound, necessitating proper ventilation and hearing protection. This method also creates clouds of slag and fumes that could be potentially dangerous to one’s health without appropriate extraction systems.

Ultimately, plasma cutting is mainly restricted to conductive metals, excluding non-metals such as plastics and wood. These constraints remind us of the cutting process realities concerning the project needs and the available technical limitations.

How does CNC plasma cutting enhance the cutting process?

CNC plasma cutting is made efficient with the combination of computer numerical control plasma cutting that increases the accuracy and precision of the cut as well as the repeatability of the cut to be done on complex shapes. The automation offered by CNC systems drives productivity in precise detail while minimizing human error, which makes it very useful for large-scale or intricate projects. It also allows for faster cutting speed, thus improving overall workflow efficiency.

Integrating CNC technology with plasma-cutting machines

While integrating CNC technology into plasma cutting machines, I focus on a few essential parts to optimize the performance. First, I ensure that the plasma cutter and the CNC system are compatible for precise communication and proper control. Secondly, I look at the type and thickness of the material as it affects the cutting parameters and the quality of the cut. Lastly, I use an application designed for CNC plasma cutting that optimizes the workflow by providing easy input of elaborate designs and making real-time adjustments. These steps improve the accuracy, efficiency, and productivity of cutting operations.

Improving cut quality and speed with CNC plasma cutters

Key factors that affect the cut quality and operational speed of CNC plasma cutters must be efficiently managed onboard. Here are a few techniques to get the most optimal results:

Maintain Proper Torch Height

Proper torch height is crucial for minimizing dross and ensuring a clean cut. Set the torch 1.5 to 2 mm above the material surface using the height control system. This range ensures reduced heat distortion and enables proper arc formation.

Control Your Cutting Speed

The cutting speed primarily impacts the quality of the edge. The speed should be adjusted depending on the type and thickness of the material:

With a plasma power source set for 10 mm of mild steel, the cutting speed can be set somewhere around 60 to 80 inches per minute (IPM)

With a thinner middle range of about 3-5 mm, the cutting speed can be increased for smooth edges up to 150-200 IPM.

Set Your Nozzle Diameter and Amperage Appropriately

The precision of the plasma arc is determined by controlling the diameter of the nozzle and the amperage output of the plasma arc. A smaller nozzle can be used to cut thinner materials more precisely.

Amperage for the thickness of steel should be appropriately matched. Reasonably, 40 – 50 amps would be matched for 6 mm steel, while 90 – 120 amps would be matched for 12 – 15 mm steel. Using excessive amperage might result in wider kerf widths, which should not be the case.

Check that the gas flow and pressure are set to an appropriate level.

Steel cutting has advanced using plasma arc, achieved by proper gas settings. The standard setting is 70-90 psi, roughly 4.8-6.2 bar compressed air. Remember to ensure the gas supply is clean and dry, as this will affect the cut quality.

Regular Checks and Maintenance of Consumables.

For electrodes and nozzles, worn usable parts can substantially reduce arc and cut precision in the practical domain. Make regular checks and maintenance for these components and replace them as required.

The compound application of these techniques will increase the productivity and accuracy of processing with CNC plasma cutters. Appropriate settings and maintenance result in faster processing times, cleaner cuts, and increased equipment longevity.

What materials can be cut using plasma cutting techniques?

Plasma cutting can slice extensive peripherals of conductive materials such as steel, stainless steel, aluminum, brass, and copper. This method can also be applied to thin and thick sheets, making it favorable for the manufacturing, construction, and automotive repair industries. Plasma cutting’s effectiveness in conducting detail-oriented shapes and varying sheet thicknesses ensures precision.

Cutting mild steel, stainless steel, and other metals

While applying the plasma cutting technique on mild steel, stainless steel, and other metals, there are essential parameters that affect the quality of the cut as well as the efficiency of the process, such as the cutting speed, amperage, gas flow, and height of the torch. Below, I explain the reasonable parameters in brief sentences.

Amperage for Thin Materials Such as Steel and Stain Steel:

Under 1/4 inch metallic thickness – 20–45 amps.

1/4 to 1/2 inch of medium-thickness metallic parts – 45–85 amps.

More than 1/2 inch thick parts – 85–200 amps.

Gas Flow:

Air-cutting appliances are suitable for most metals. A mixture of gas such as Nitrogen or Argon-Hydrogen is best for clean slicing regarding stainless steel and aluminum as this reduces oxidation.

Adjust the gas to between 50 and 100 psi, depending on what the plasma cutter maker has suggested.

Torch Height:

Leave a 1/16—to 1/8-inch gap between the torch’s nozzle and the workpiece to ensure accurate cuts without damaging the consumables.

Plasma cutting retains beguiling precision by achieving the needed functional parameters while making metal cuts. Always refer to the manual for accurate machine instructions and safety measures.

Limitations on materials and thickness in plasma cutting

Like most processes, plasma cutting has strengths and weaknesses. The primary limitation is the materials and thicknesses it can accommodate. The process works exceptionally well with conductive metals, including steel, stainless steel, aluminum, brass, and copper. However, it does not extend to non-conductive materials such as plastics or wood because nonelectric materials cannot be penetrated.

The power level of a given machine determines how thick a piece can be when plasma is cut. Basic machines can effectively cut up to 1/4 inch (6 mm). More advanced machines can range from 1/2 inch (12 mm) to 1 inch (25 mm). The most advanced industrial plasma cutters can sever materials up to 2 inches (50 mm) thick, provided the cuts are not high-end and precise. Quality cuts are generally limited to around 1-1/4 inches (30 mm).

The type of gas used affects amperage, as does the quality of the consumables, making cutting thickness an extremely variable process. For instance:

Machine Power

20-40amps, suggests a capacity of 0.25inches or 6mm

40-80amps, recommends a capacity of ½ inches to 1 inch, or 12-25mm

For over 100 amps, a capacity of 2 inches or 50mm is set.

Cut Quality

The best cuts are produced underneath the machine’s recommended thickness range, often within other constraining limits.

When cutting thick materials, the two other constraints to consider are the presence of dross and the squareness of the edge, as they contribute to quality deterioration that occurs past the machine’s optimal limits. Remember to check the equipment specifications and settings for efficiency and safety. Always set the equipment by thickness and material.

How does plasma cutting compare to other cutting methods?

Unlike laser cutting, oxy-fuel cutting, and waterjet cutting, plasma cutting rises above the rest due to its simple and quick approach to cutting applications. With little to no beats of waste, it precisely cuts electrically conductive materials like steel, aluminum, and stainless steel. Furthermore, plasma cutting is less complicated than oxy-fuel cutting since it quickly cuts non-ferrous metals. Waterjet cutting may be slower, but it can tackle a more extensive selection of materials. Plasma cutting is more affordable for intricate projects as it can tackle more cost-efficient materials than laser cutting, which is immensely accurate but only manageable with non-metallic materials. All in all, plasma cutting is a simple yet sophisticated technique that can be used for various industrial and fabrication needs.

Plasma cutting vs. laser cutting: Pros and cons

Oxy-fuel cutting and waterjet cutting: Alternatives to plasma.

Carbon steel is one of the metals for which oxy-fuel cutting is widely used. This method involves using pure oxygen and a fuel gas, like acetylene, propane, or natural gas. The mixture enables the production of a flame with high temperatures, making cutting easy. The flame is applied to the oxygen that is reacted with the heated metal. Iron oxide is formed and subsequently blown away, leaving behind a cut. Oxy-fuel cutting is effective in cutting metals that are thicker than one inch (25mm) and, in some situations, can cut much more, up to 24 inches (600 mm), though it is most effective at that. Oxy fuel cutting method is unsuitable for non ferrous like aluminum or stainless steel due to their resistance to oxidization, however, it is cost effective and portable.

Key Parameters of Oxy-fuel Cutting:

Cutting Thickness: Can be done effectively in 1 to 24 inches (25 to 600 mm).

Gas Types: Oxygen together with acetylene, propane, or natural gas.

Cutting Speed: Somewhat slower than plasma or laser cutting.

Material Suitability: Good for carbon steel; poor for nonferrous metals.

Waterjet Cutting

Waterjet cutting services involve a specialized high-pressure water stream that contains abrasive materials, like garnet, to cut through various substances. Water jet cutting is one of the most universal cutting methods available. It allows the cutting of metals, plastics, stone, glass, and composites with equal effectiveness. Waterjet cutting does not use oxy-fuel or plasma, which means it does not produce heat, making it preferred for sensitive materials. It also achieves fine detail at tight tolerances, generally within ±0.005 inches (±0.13 mm). Nevertheless, water jet cutting has the drawbacks of slow cutting speed and high operation costs because of the abrasive materials and high pump pressure.

Essential Considerations in Waterjet Cutting:

Cutting Thickness. The cutting thickness of soft materials can exceed 300 mm (12 inches), but it usually does not exceed that figure for metals.

Pressure. Standard working pressure is up to 90,000 psi (6,200 bar) for standard operations.

Material Suitability. This process works on stone, metals, glass, plastics, and composites.

Tolerances. This method has high precision tolerances, often ±0.005 inches (±0.13 mm).

Heat Affected Zone. None, because cutting is done cold.

Oxy-fuel and waterjet cutting are plausible substitutes for plasma cutting and are the best methods for their respective tasks. Oxy-fuel is perfect for cutting large, thick pieces of steel, while waterjet provides high precision and a good range of materials for projects involving fragile or heat-sensitive parts. Knowing the technical aspects of your project enables you to choose the cutting technology that most closely meets your material and design requirements.

What safety precautions should be taken when using a plasma cutter?

When using a plasma cutter, please follow these safety precautions:
Different safety policies must be implemented when working with welding plasma cutters. These include:

Wear Proper Personal Protective Equipment (PPE): Use a face shield or goggles rated for plasma cutting, flame-resistant clothing, heavy gloves, and closed-toe shoes to shield from sparks and ultraviolet rays.

Use proper ventilation: The cutter must be operated in a well-ventilated area so as not to breathe in the hazardous fumes or gases emitted during cutting.

Inspect Equipment: All cables, hoses, and connections should be checked regularly for damage. Ensure the machine is properly grounded to avoid electrical hazards.

Avoid flammable materials: Flammable materials should be kept out of the workspace, and ready-to-use extinguishers should be kept nearby.

Use the Correct Settings: To avoid overheating and unnecessarily increasing risks, the plasma cutter should be set to the correct amperage that matches the cut material.

Maintain Focus: While operating the plasma cutter, always stay alert and avoid distractions. Always turn the cutter off when not in use. Never allow any person to manage the cutter without proper authorization.

By following these regulations, all tips for risk mitigation no longer need to be a concern, resulting in a perfect and safe environment to work with the cutter.

Essential safety gear for plasma cutting

Getting the best plasma cuts is not as simple as just cutting plasma; safety comes first. The most troublesome of cuts comes with unbearable amounts of sparks and heat. Thus, all personnel must don a helmet and face shield, a set of heat-resistant gloves, a flame-resistant jacket, a set of steel toe boots, and respiratory protection in the form of a mask or respirator. These ensure optimum safety throughout the process. The helmet, gloves, and jacket will protect one from burns, the face shield and jacket keep the eyes behind the face shield from getting burnt, and the steam off the glowing headset will feel so good!

Workplace safety considerations for plasma cutting operations

As mentioned, plasma cutting is not a simple task and thus comes with multiple dangers if not handled with care. The step that burns the most is ensuring a place with ample ventilation to extract the dew from the air. Without it, fume and gas accumulation can turn dangerous and explode with Little to no warning. The first thing that comes to mind with violence getting rid of the workplace is fume extraction. A clean-up of sorts is undoubtedly needed to remove and eliminate Flammable objects. The fresh area will also require objects to be cut beforehand to prevent further hazardous encounters.

Electric safety practices must be followed, as the plasma cutter works with high voltage. All cables and connections should always be functional and not damaged. The equipment should also be kept dry to eliminate the danger of short circuits or electrocution. The operators should have proper training on using the equipment and handling emergencies.

While adjusting the plasma cutter’s setup, ensure the workpiece is mounted so it does not move and stays firmly in place. Everything should be adequately grounded to avoid high-voltage electromagnetic and electrical hazards. Also, follow the manufacturer’s instructions regarding air pressure and power settings. The standard air pressure depends on the type and thickness of the metal being cut and ranges between 60 and 120 psi.

Lastly, access to a properly maintained fire extinguisher ration for electric or metal fires is essential in emergencies. Always go over safety steps and check for any possible risks to ensure everything works properly and there are no dangers for anything or anyone. These steps and proper safety wear produce a safe and productive working environment during cutting.

How can I optimize my plasma-cutting technique for better results?

To improve your results, combine precision, equipment settings, and maintenance to improve your cutting technique. The first step involves picking the right torch tip size and ensuring the consumables are in good condition, as worn tips can get you inconsistent cuts. Next, change the cutting speed along with the amperage based on the material’s type and thickness; remember, if you’re cutting too slowly, you’ll get excessive slag, and if you’re cutting too fast, you’ll get uneven edges. Lastly, remember to maintain the torch-to-workpiece distance, as this affects the cut quality and stability of the arc. Subsequently, clean the nozzle regularly and check for any obstructions to ensure consistent airflow. You must practice steady hand movement or use guides to achieve clean and accurate cuts. By changing these few factors, the effectiveness and quality of plasma cutting can be increased substantially.

Tips for improving cut quality in plasma cutting

1. Select the Right Consumables

• Ensure the torch tip, nozzle, and electrode are in good condition.
• Replace worn consumables to prevent irregular cuts.

2. Optimize Cutting Speed

• Use the recommended cutting speed for the material.
• Aim for approximately 60–120 inches per minute (IPM) for standard mild steel, depending on thickness.

3. Adjust Amperage Appropriately

• Match the amperage setting to the material thickness.
• Example: For 1/4″ steel, use 40–60 amps.

4. Maintain Proper Torch Height

• Keep the torch-to-workpiece distance between 1/16″ and 1/8″ for optimal arc performance.
• Use a height control system if available.

5. Ensure Adequate Airflow

• Most systems use clean, dry air with a 90–120 PSI pressure.
• Check filters and compressors regularly.

6. Practice Steady Cutting Movement

• Use a guide if necessary for straight lines or consistent patterns.
• Avoid weaving or erratic movement during cuts.

7. Minimize Slag Formation

• Adjust cutting speed—slower speeds create more slag, while faster speeds may leave edges rough.
• Fine-tune settings to balance precision and clean edges.

8. Inspect and Maintain Equipment Regularly

• Clean the nozzle and torch after each use to avoid blockages.
• Perform routine maintenance as per the manufacturer’s guidelines.

You can consistently achieve precise and high-quality cuts by implementing these tips and monitoring your process.

References

Plasma cutting

Plasma (physics)

Gas

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Frequently Asked Questions (FAQ)

Q: How does a plasma cutter work?

A: A plasma cutter creates a high-temperature, electrically conductive gas called plasma. The process involves using compressed gas and an electrical arc to ionize the gas, creating plasma. This plasma is directed through a narrow nozzle at high speed, effectively cutting through metal. The pilot arc initiates the cutting process, and once the main arc is established, it can cut through various thicknesses of conductive materials.

Q: What types of gas are used for plasma cutting?

A: Plasma cutters use various gases depending on the cut material and the desired outcome. Common gases include compressed air, nitrogen, oxygen, and argon-hydrogen mixtures. Each gas has specific properties that affect cutting speed, quality, and cost. For instance, oxygen is often used for cutting mild steel, while nitrogen is preferred for stainless steel and aluminum.

Q: How does plasma cutting work compared to welding?

A: While plasma cutting and welding involve high heat, they serve different purposes. Plasma cutting is a process that uses ionized gas to cut through metal, whereas welding joins metals together. Plasma welding does exist, but it’s a separate process from cutting. In plasma cutting, the goal is to precisely separate materials, while welding aims to fuse them. The plasma torch head in cutting is designed to direct the plasma for cutting, not joining.

Q: Can plasma cutters cut thick metals?

A: Yes, plasma cutters can cut thick metals, but their capability depends on the machine’s power. Industrial plasma cutting machines can cut metals up to 6 inches thick. The process involves multiple passes or specialized high-power systems for thicker materials. The ability to cut thick metals makes plasma cutting a versatile option for various industrial applications.

Q: What is a CNC plasma cutting machine?

A: A CNC plasma cutting machine combines plasma cutting technology with computer numerical control (CNC). This integration allows for precise, automated cutting of complex shapes and patterns. The CNC system controls the movement of the plasma torch head over a cutting table, following pre-programmed designs. This technology enhances plasma cutting accuracy, speed, and repeatability, making it ideal for mass production and intricate designs.

Q: What materials are commonly used for plasma cutting?

A: Plasma cutting is primarily used for cutting conductive metals. Common materials include mild steel, stainless steel, aluminum, copper, and brass. The process is particularly effective for cutting sheet metal and plates. While plasma cutting can be used on various thicknesses, it’s most efficient on materials up to about 1 inch thick for handheld units and much thicker for industrial systems.

Q: How does plasma cutting compare to laser cutting?

A: Both plasma and laser cutting are thermal cutting processes, but they differ. Plasma cutting uses ionized gas, while laser cutting uses a focused light beam. Laser cutting typically offers higher precision and can cut non-conductive materials, but it’s generally more expensive and slower on thicker materials. Plasma cutting is often faster and more cost-effective for thicker conductive metals but may not achieve the same level of precision as laser cutting for incredible details.

Q: What are the disadvantages of a plasma cutter?

A: While plasma cutters are versatile and efficient, they have disadvantages. These include the potential for a wider kerf (cut width) than laser cutting, which can affect precision on fragile materials. The heat-affected zone around the cut can be larger than with some other methods, potentially affecting the material properties. Additionally, plasma cutting is limited to conductive materials and may not be suitable for materials sensitive to heat distortion. The initial cost of high-end plasma-cutting systems can also be significant.