Best Plasma Cutter: Complete Buying Guide & Reviews

In a variety of machining projects having the best plasma cutter is critical.

You need something that can get through anything and that will easily carve out precise pieces to fit with the project you are working on.

While these are generally not household tools, there are some household versions and having the right one means being able to get the job done properly.

In a Hurry? Here’s Our Favorite:

Last update on 2022-06-23 / Affiliate links / Images from Amazon Product Advertising API

Best Plasma Cutters

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Lotos LTP5000D Plasma Cutter

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This system is designed to be portable with a handle that makes it easier to carry around with you. It uses non-hazardous compressed air so it’s safe to use in a range of different areas and it can be used to cut through materials like stainless steel, alloy steel, mild steel, copper and aluminum.

The pilot arc torch can even cut through rough, rusty or painted surfaces with minimal slag and uses a German cooling system to provide higher quality. The MOSFET transistor makes sure that it gives you exactly the same performance every time and that it can cut through thin material without damage but still cut through thick materials with the same precision.

The dual voltage means that it can run on 220V50/60Hz or 110v50/60Hz though this does require an additional piece that is not included. You will get a plasma torch, ground clamp and caliper, air hose, air hose connection and air regulator included in the system. It’s a 50 amp digital inverter air plasma cutter.

Things We Like:

  • Dual voltage compatibility
  • Cuts through variety of materials
  • Non-hazardous compressed air
  • ½” clean cut
  • Things We Don’t Like:

  • Slag sticks to tip
  • Doesn’t work quickly on heavier material
  • Ground clamp is weak
  • Super Deal Plasma Cutter

    Last update on 2022-06-23 / Affiliate links / Images from Amazon Product Advertising API

    This unit operates with a high duty cycle which is designed to cut down on the amount of power being consumed, making it more efficient than other options. It’s made with heavy duty iron to ensure it’s durable and ready for just about anything, including professional applications and hobbyists.

    There’s a digital display that shows the DC output and lets you know what’s going on with the unit at all times and even a front panel air pressure gauge that lets you know if you can continue going. The unit is made with over heat and over voltage protection as well as under voltage protection and lack of compressed air pressure protection.

    If it’s not safe to use you can feel comfortable that it’s not going to let you use it. It even comes with the wire and mask that you need to keep yourself better protected. Suitable for sheet metal fabrication, industrial use, automotive work, duct work and more, this unit is rated for 110V/60Hz and provides a current range between 20 and 50 Amps. It can cut material up to 12mm thick.

    Things We Like:

  • Generic torch that is compatible with other units
  • Lightweight and compact
  • ½” clean cut
  • Includes everything to get started
  • Easy to read gauges and screen
  • Things We Don’t Like:

  • Manual included is not helpful
  • Emits UV rays
  • Does not work well with moisture
  • Hobart 500565 Airforce 27i Plasma Cutter

    Last update on 2022-06-23 / Affiliate links / Images from Amazon Product Advertising API

    This unit is more expensive than most of the options we have here, but it’s definitely going to give you some great features. It has a multi voltage plug that lets you use either 120V or 240V power and it can cut just about anything up to 5/8” with no problem. The fan runs when you need it to and never any other time, which means that it pulls in a whole lot less dust and debris, keeping the unit clean and running properly for a much longer time. It gives a precise cut and thin kerf, which leaves behind less slag.

    The wind tunnel technology also makes sure that when the fan is running and anything is pulled through the unit it’s not going to cause damage to the internal components, which is always an important aspect to keeping the unit working longer. It’s lightweight and uses an inverter-based design to make sure you get the job done the way you want. It’s easily portable and carries a 5 year warranty that says that it will continue to work just like you want for a long time.

    Things We Like:

  • Dual voltage options
  • Fan runs only when needed
  • Wind tunnel technology
  • 5 year warranty
  • Inverter based design
  • Things We Don’t Like:

  • Manual fan
  • Hose can be a little short
  • Everlast Power Equipment Plasma Cutter

    Last update on 2024-05-02 / Affiliate links / Images from Amazon Product Advertising API

    This cutter is less expensive than some of them we’ve looked at (and definitely less than our last one) but it still provides you with some excellent features. First, it’s a dual voltage system that runs on either 110V or 220V and offers 50 amps of power. It’s an inverter design cutter and has a quick and reliable startup so you can get going a whole lot faster.

    It also works on a low level of current, which means you’re not going to spend a fortune powering it up. This unit comes with a 3 year warranty on parts and labor that says it’s going to be high quality and last a long time. It even has a 30 day money back guarantee that says it’s going to be just what you want or you can return it for a refund.

    The dials on the front let you adjust it right where you need it to be and the air pressure gauge keeps you informed while you’re working. It can create clean, low dross cuts and has a 6 foot power cord that gets you plenty of distance no matter what you need.

    Things We Like:

  • Dual voltage option
  • Low level current required
  • 3 year warranty
  • Easy adjust dials
  • 6 foot power cord
  • Things We Don’t Like:

  • Ground lead is short
  • Can be a little expensive for hobbyist
  • Ideal for hobbyists
  • Everlast SuperUltra 206si Plasma Cutter

    Last update on 2022-05-04 / Affiliate links / Images from Amazon Product Advertising API

    This lightweight unit is portable and provides dual voltage compatibility, which increases the versatility of the unit. It uses a pilot arc function to cut through materials and can work with a wide range of different materials. Great for entry level users, it’s powerful, with up to 200 amps of welding power.

    It’s able to work with a number of different welding rods for stick welding. It’s even able to cut through materials up to ½” thick. For those looking for general features and capabilities this is a great option and it offers a 5 year warranty that says it’s going to continue to work just the way you expect.

    If there’s ever any problems you can send it back to the company to take care of. For those who want a good quality unit without having to spend a lot of money you’re getting two features in one and you’ll need very little effort in order to accomplish the tasks that you need. It’s also small for the amount it can do which means it fits just about anywhere you need.

    Things We Like:

  • Cuts through ½” materials
  • 5 year warranty
  • Dual voltage
  • Plasma cutter and welder
  • Excellent welding power
  • Things We Don’t Like:

  • Torch is not molded well
  • Doesn’t provide ideal finish
  • Can leak argon into machine
  • Features to Consider

    You want to know the different features that are out there when it comes to any type of plasma cutter you’re buying for personal or commercial use. You want a tool with all of the best features and that’s why we’ve compiled a list of several of the features that you should be looking at. With any of these it’s going to also depend somewhat on personal preference, so you can make sure you’re ready for the type of projects you’re going to do without spending more than you need to.

    HF vs. Contact Start

    HF is high frequency start and provides you with a slightly different startup aspect than contact start. High efficiency start is not ideal for any electronic equipment because it tends to interfere with the controls that are used.

    A contact start creates a visible pilot arc and it doesn’t cause any kind of electrical interference, which is important in a number of different types of projects. You’ll want to look at where you’re using the unit to decide which option is better for you.

    Materials to Cut

    Just about any plasma cutter will get through different materials, but some of them are going to do it a little better than others. Here is a how to guide we did highlighting the different methods of cutting stainless steel. You want to make sure that you have a unit that’s designed for the right type of material and definitely for the thickness that you’re looking at.

    Hobart 500565 Airforce 27i Plasma Cutter

    Consider what the thickest pieces of material are that you’re going to cut and then look for a cutter that can easily handle that size. You don’t want to have a system that can’t handle the type of work that you’re going to need, after all.

    Voltage Rating

    Look for something that has a voltage rating that’s compatible with your needs. There are actually several out there with a range of different sizes and requirements so you can easily find something whether you have a very low voltage or a very high one.

    There are a lot of different plasma cutters that are compatible with dual voltages as well, and the specific voltages vary slightly. Take a look at the area you’re going to use the cutter in and just how much power you have available and go from there.

    Duty Cycle

    You need a cutter that has a good range for the duty cycle. This is the amount of time that it will run without needing to cool down. The longer the amount of time it can run the more work you’re going to be able to do without having to stop and take a break.

    If you’ve got a really big project you don’t want to be stopping every 5 minutes just so the cutter can cool down and be ready to go again. On the other hand, if you’re only going to do very small tasks having a short duty cycle might not be as important and you can save a little money.

    Cutting Speed

    Another feature is the speed that it can cut at. Just because a tool can cut through a thick piece of metal doesn’t mean that it can do so quickly. You’ll want something with at least a moderate level of speed so you can make sure that it can take care of anything you want it to do. The faster the speed the more you’re likely going to pay for it but you’ll be able to get projects done more quickly and that means you get to move on to the next project (or something else entirely).

    Wrap Up

    When it comes down to it you’re going to want the best tool you can get and that’s going to be the Hobart 500565 Airforce 27i Plasma Cutter. This cutter is capable of doing just about anything you could want it to do from cutting through thicker materials to cutting through more types of materials. It’s definitely going to accomplish whatever task you set in front of it, but it’s definitely the most expensive option that we have available as well.

    If you’re looking to save a little money there are plenty of other options out there but the really unique option is going to be the Everlast SuperUltra 206si Plasma Cutter. This one is going to give you a plasma cutter and a welder all in one, so you’ll be able to accomplish several different tasks with no trouble at all. There’s definitely nothing to lose here and if you’re looking for tools to get you started with your own work then this is definitely a great way to go.

    If you want to pick up our top pick check it out right here.

    About Gus Donaldson

    I built houses for over 30 years and recently retired. I've made lots of mistakes and hopefully teach you not to make the same ones. I still love to build and have a garage workshop that I use for hobby projects like the walnut bookshelf I made for my wife. I like to write and let people know that working with your hands and tools does not need to be intimidating.

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