The Ultimate Guide to Plasma Cutting: Industry and Safety.

Welding is crucial to many industrial productions. Plasma cutting systems emerged in the 1960s as an innovative method of welding. At first, the plasma system in its commercial form processed stainless steel. Industries welcomed the new system with open arms for its efficient and clean cut. Today, a range of consumers like professional metal workers and hobbyists buy the once exclusively industrial tool. Plasma Cutters come in various types, such as the Hypertherm powermax 45 and other items.

The Process

Plasma cutting cuts through electrically conductive materials through hot plasma. When the atoms lose their electrons, they emit heat around the plasma that flows through it like a torch. For the process to work, plasma gas forms when electricity and compressed air are combined. Plasma cutting systems work with metals like steel, stainless steel, aluminium, copper, and brass.

 Plasma cutting comes in handy with artistic production, automotive repair, industrial construction, metal centres, manufacturing. These industries use both the manual and the mechanized version of plasma cutters. The type of equipment depends on the material and mobility.

Pros of Plasma Cutters:

Plasma cutters save both time and energy. Hiring a professional contractor for the welding job is expensive as they charge by the hour. Plasma cutters, on the other hand, cut the cost and time in half.

Since a plasma cutter has developed to be computer-operated, the precision of the machine is undefeated. There is little room for error. For underwater welding works, plasma cutters are preferable as they use lower heating levels. The noise level of the plasma cutter is also negligible when compared to other cutting technologies.

Safety Makes Sense:

Careful operation of a powerful tool like the plasma cutter and Hypertherm powermax 45 ensures safety. The standard safety precautions include:

Keeping away from the work area and cutting area

A handy fire extinguisher

Professional training and experience.

Typically, a shielded plasma torch has an electrode and nozzle. Most of the other types of equipment are unshielded with an exposed nozzle and open electrode. But even with these protective tools of welding, there are particular on-field safety procedures. Here is a gist of the list of items to keep in handy and safety tips for better protection:

Cutting Glass and Shield:

The face shield and the glass protects the head, eyes, and face from radiation, sparks, and intense light. Even though plasma cutters are less damaging, these protective measures are standard procedures in welding. Eye protection must have filter lenses with an appropriate shade number. A shade number of six is suitable for plasma arc welding of above 20 amperes.

Dimming the lights:

Arc rays produce ultraviolet and infrared rays. Screens and lighting systems can protect the welder from the flash to maintain proper eyesight.


Even if the equipment is computer-assisted, the cutting work is a hands-on job. Hands may be vulnerable to heat, sparks, and burns without heat-resistant gloves.


The head coverings use flame-resistant materials that protect the welder from sparks and flames to the hair and shoulders.

Non-flammable Apparel:

A leather apron or a coat with non-flammable properties protects the skin from slags, heat sparks, et cetera.

Plasma cutting is one of the safest metal cutting tools. Additionally, a hobbyist reading this article must thoroughly read the user’s manual to avoid any accident. OSHO standards and ANSI Z49.1, “Safety in Welding, Cutting and Allied Processes”, are other reference materials that can be useful for a rookie

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