How to cut metal with a plasma cutter?
Plasma cutting is one of the fastest and most precise methods for cutting metal. Whether you’re working with mild steel, stainless steel, or aluminium, a plasma cutter offers clean, accurate results with minimal preparation and waste. The process uses an ionised gas, plasma, to melt and blow away metal along a precise path, making it ideal for both industrial fabrication and workshop applications. Understanding the correct technique and equipment setup ensures maximum efficiency, safety, and cut quality.
To cut metal with a plasma cutter, you first need a reliable power source, a plasma torch, and compressed air or a suitable gas mixture. When the trigger is activated, an electrical arc passes through the gas, converting it into plasma, a superheated jet capable of reaching temperatures above 20,000°C. This plasma stream melts the metal instantly, while the high-velocity gas blows away the molten material, leaving a smooth, narrow cut known as a kerf.
The cutting process can be performed manually or automated with CNC (Computer Numerical Control) systems for repeatable, precision work. Modern CNC plasma machines, such as those developed by CR PLASMA, integrate Hypertherm XPR technology and in-house control systems for direct DXF file processing, eliminating the need for expensive external software or annual licence fees. These systems deliver consistent motion, clean edges, and efficient production for both light fabrication and heavy-duty industrial operations.
Proper setup and technique are essential for high-quality cuts:
Prepare the workpiece … clean the metal surface and ensure proper grounding.
Set the correct amperage and gas flow … adjust settings based on material type and thickness.
Maintain a steady hand or programmed torch path … keep a consistent torch-to-material distance.
Cut at the right speed … too fast leaves uncut edges, too slow causes excessive dross.
Inspect the results … remove slag and verify accuracy after cutting.
Fast, precise metal cutting … ideal for steel, stainless steel, and aluminium.
Extreme-temperature plasma arc… instantly melts and separates material.
CNC automation … ensures repeatable accuracy and smooth edge quality.
Hypertherm XPR integration … achieves cleaner cuts with TRUE HOLE® capability.
Direct DXF file processing … load and cut immediately with CR PLASMA’s controller.
Cost-efficient operation … no annual licence or software fees required.
Safe and efficient workflow … proper setup guarantees professional results every time.
With the right equipment and technique, plasma cutting delivers unmatched versatility and precision for modern fabrication. CR PLASMA systems make the process even easier, combining advanced control technology with Hypertherm’s plasma power for superior performance and long-term reliability.
