UNDERSTANDING PLASMA CUTTING: COMPATIBLE MATERIALS AND LIMITATIONS
November 5th, 2025
When plasma cutting was first introduced in the 1960s, it fundamentally changed how metal plate was processed. Prior to plasma, fabricators relied primarily on mechanical cutting and oxy-fuel cutting—processes that generate significant sparks, slag, heat distortion, and debris, all of which increase safety risks and post-processing time. Plasma cutting dramatically reduced these issues by offering faster cuts, cleaner edges, and improved operator safety, making it a cornerstone technology in modern metal fabrication.
How Plasma Cutting Works (2026 Perspective)
Plasma cutting uses a high-energy electrical arc forced through a constricted nozzle, where compressed gas—most commonly air, oxygen, or specialized gas mixtures—is ionized to form plasma. This plasma jet reaches temperatures exceeding 20,000°C, instantly melting the metal while the high-velocity gas blows molten material away from the kerf.
Modern plasma systems feature advanced arc control, digital height sensing, and intelligent gas regulation, resulting in consistent cut quality, reduced bevel angle, and longer consumable life compared to early plasma systems.
What Can Plasma Cutters Cut Today?
Because plasma cutting relies on electrically conductive materials, it is suitable for a wide range of metals, including: mild steel, stainless steel, carbon steel, expanded steel, hardox, aluminium, copper, brass and other ferrous materials.
With today’s high-definition and precision plasma systems, cutting ranges have expanded significantly. Modern heavy-duty CNC plasma systems can reliably process material from thin gauge sheet up to 2 inches (50 mm) or more, depending on power supply, torch technology, and edge quality requirements. For thicker materials, plasma remains a highly productive alternative to oxy-fuel, especially when speed and flexibility are priorities.
What Plasma Cutters Cannot Cut
Plasma cutting is not a universal solution. Because the process depends on electrical conductivity, non-conductive materials cannot be cut, including: wood, glass, plastics, rubber, ceramics and some metals with poor conductivity such as lead, tin, tungsten, and certain alloys.
Advantages of Modern CNC Plasma Systems
In 2026, plasma cutting is almost exclusively paired with CNC automation in professional fabrication environments. CNC plasma tables allow operators to import CAD files directly, enabling precise, repeatable cuts with minimal manual intervention.
Key benefits include: Faster production speeds, Consistent cut quality across long production runs, Reduced labor and rework, Advanced nesting for material optimization and Integration with drilling, tapping, marking, and beveling systems.
High-definition plasma technology now delivers edge quality that rivals laser cutting in many thickness ranges, particularly in medium to thick plate applications.
Choosing the Right CNC Plasma Machine for Your Shop
CNC plasma cutting tables are used across a wide range of industries, from custom metal fabrication and structural steel to shipbuilding, heavy equipment, and industrial HVAC. Selecting the right system depends on several factors, including material type, thickness range, production volume, and required edge quality.
For high-throughput operations or shops running multiple shifts, a robust, industrial-grade plasma system with a high-amperage power source is essential. Smaller or intermittent operations may benefit from a lighter-duty table without sacrificing accuracy.
A widely accepted rule of thumb remains relevant in 2026:
Choose a CNC plasma system capable of cutting at least twice the maximum thickness you plan to process regularly. This ensures better cut quality, longer consumable life, and future scalability as production demands increase.
