Jonathan Lloyd

Cutting torch vs plasma cutter

The main difference between a plasma cutter and a cutting torch

The main difference between a plasma cutter and a cutting torch is that a cutting torch uses two gases(oxygen and propane/acetylene) to cut low carbon steel/mild steel. A plasma cutter uses electricity to create an arc and compressed air to cut through a larger range of metals.

Another clear indication between a plasma cutter and a cutting torch is the different torches used. A plasma cutter has this short L-shape torch where a cutting torch has 2 two 3 adjustable valves, a lever, and is a lot longer.

Plasma cutter vs cutting torch chart

–	Plasma cutter	Cutting torch
Accuracy	High	Medium
Cost (Average New)	$200 – $500	$70 – $450
Requires power	Yes	No
Gases used	Compressed air	Oxygen and propane/acetylene
Max thickness handheld	2inch / 50mm	4inch / 100mm
Min thickness handheld	1/32inch or 0.8mm	1/8inch or 3mm
Portability	Low	Medium – High
Eye protection	Welding helmet	Tinted safety glasses
Learning curve	Medium	Medium
Ease of use	Medium	Hard
Cut stainless	Yes	No

Plasma cutter

How does a plasma cutter work

A plasma cutter works similarly to a welding machine where you have two polarities to create an arc. This arc is used to heat the metal and once the metal is heated a stream of compressed air is used to blow away the molten metal to create a cut.

Benefits of a plasma cutter

The main benefit of a plasma cutter over an oxy-fuel cutting torch is that a plasma cutter can cut non-ferrous metals such as stainless steel, where a cutting torch can’t.

A plasma cutter is also easier to use, learn and set up than a cutting torch. This is due to it not having to regulate two gases to get the perfect flame for cutting.

Easier to learn
Easier to set up
Easier to use
Can cut non-ferrous metals
Safer to use over oxy-fuel
Best for home use
No gases burnt

Disadvantages of a plasma cutter

The main disadvantage of a plasma cutter has over an oxy-fuel cutting torch is the fact that a plasma cutter needs to be connected to electricity and requires compressed air that is another extra expense.

Needs electricity supply
Needs compressed air supply
Not easily portable
Limited in the thicknesses you can cut

Where to best use a plasma cutter

A plasma cutter will be best for most day-to-day cutting in a workshop ranging from 1/32 inch to about 2-inch metal thickness. Another great use of a plasma cutter that a cutting torch can’t do is cut stainless steel.

Cutting stainless steel
Cutting metal 1/32 inch – 2 inch
Day to day workshop works
Great for DIY or hobbyist

Cutting torch

How does a cutting torch work

Oxy-fuel cutting works differently from a plasma cutter but has the same concept. It uses a fuel gas which can be propane or acetylene. This fuel gas mixed with oxygen is used to heat the metal and a stream of compressed oxygen is then used to blow away the heated metal.

The chemical process that is used to create the cut requires the metal to be able to oxidize, hence the oxygen. That means you can only cut low carbon/mild steel with this process.

Benefits of a cutting torch

A cutting torch is a lot more portable than a plasma cutter, and you can easily change the thicknesses a cutting torch can cut by simply changing the nozzle size. Where a plasma cutter you will be limited to the max amperage it can output.

Large range of thicknesses you can cut
Easily change max thicknesses it can cut
More portable (Small and large cylinders available)
No power required
Can be used to heat metal

Disadvantages of a cutting torch

Constantly having to exchange gas cylinders when they empty can get annoying especially if you are cutting metal where a plasma cutter can be used also.

Changing out gas cylinders when empty
Can’t cut non-ferrous metals
Harder to use
Harder to learn

Where to best use a cutting torch

A cutting torch is best used when cutting thicker metals above 2 inches or if you don’t have access to a plasma cutter or electricity like site work. You can also use a cutting torch to heat metals for bending.

Heating metal for bending
No access to electricity
Cut metal above 2 inches

The different products available

One thing to consider when buying a plasma cutter is the number of amps it can produce. This is because the number of amps directly contributes to the max thickness you will be able to cut. For example, a 50 amp machine won’t be able to cut a 2-inch plate.

This results in a ton of different shapes and sizes of machines you can buy and be a bit confusing when you want to get a plasma cutter.

Where a cutting torch has the two gasses and only a quick change of nozzles can allow you to change the max thickness you will be able to cut.

I have a great table on my post on how to set up and use a cutting torch where I indicate the nozzle size you need for the plate thickness. I recommend bookmarking it for reference, I still tend to look back on it myself now and then.

Conclusion

Both of them have their advantages and disadvantages which is why it will be great to have both so you can cut metal no matter what the situation requires.

Personally, I have worked a lot more with a cutting torch than a plasma cutter because it is cheaper and more portable because it doesn’t need to be plugged in, but if you don’t move around a lot and have a dedicated place for work then a plasma cutter is the way to go.

Posts