Best plasma cutter safety tips

CNC plasma cutting is a fast, precise, and efficient cutting method. While it is straightforward and efficient to use, it still poses a series of safety risks. To minimise safety risks while using your plasma cutter, it’s important to implement the correct techniques and protocols. 

In this article, we outline the common mistakes and safety concerns with plasma cutting and share our tips for mitigating any problems. 

Stay clear of the machine

During operation, make sure all workers stay clear of the machine. This will protect them from the risk of pinching or crushing, as well as fire hazards and overexposure to the plasma arc. We also recommend installing clear signage to alert everyone of these hazards. 

Ensure proper ventilation and fume control

Plasma cutting generates hazardous fumes and particulates that can harm those in the area. A well-designed ventilation system is essential, removing these contaminants from the workspace using local exhaust systems, downdraft tables, and fume extractors.

A waterbed can also be included for fume control close to the source, capturing sparks and debris produced by the plasma arc. The water absorbs most of the heat and fumes before they escape and dissipate into the atmosphere. 

As a bonus, waterbeds also dampen noise levels, extend the lifespan of consumables, and reduce heat-related warpage.

Wear protective clothing

When operating a plasma cutter, protective clothing will minimise the risk of injury from heat, sparks, electrical hazards, and flying debris. Appropriate clothing includes full-coverage flame-resistant clothing, high-temperature gloves, rubber-soled boots, shade 5 glasses, hearing protection, and respiratory protection. 

Minimise fire hazards

Every time a plasma cutter is used, precautions must be taken to minimise the risk of fire. This includes clearing the work area, ensuring adequate ventilation, and removing any fire-prone materials. You should also have suitable fire extinguishers available in clear and accessible locations. 

For more information, read our article on the various challenges you could experience with a CNC plasma cutter.

Follow electrical safety procedures

To ensure electrical safety, you should implement proper grounding techniques, inspect all cables, use the correct voltage, and wear appropriate safety clothing. We highly recommend installing an earth stake and always wearing rubber-soled boots. When it is not in use, turn the plasma cutter off and unplug it. 

You must have a qualified professional inspect the electrical work regularly, checking all wires, connections, and components. If you are purchasing a new plasma cutter, ask our team which plasma cutting machine is best suited to your power supply. 

Emergency stop switches

A plasma cutting machine should have at least one emergency stop button to halt motion and cutting instantly. If something goes wrong, this could be the difference between a serious injury and a minor scare. 

We also recommend implementing a control system fitted with a safety relay. This will monitor the emergency stop circuit and trigger a power down if it isn’t working correctly. 

Gas cylinder safety

Always store gas cylinders in an upright position according to the manufacturer’s instructions. They should be kept in well-ventilated areas away from any heat sources, sparks, or open flames. Never use a damaged or faulty cylinder and always follow proper procedures for valve operation.

Use reliable CNC plasma cutter software

Some cheap CNC software manufacturers cut corners when developing their software, making them inefficient and difficult to use. This will impact your workshop’s output and often lead to safety issues. We recommend choosing reliable software like SURECONTROL, which has been developed for ease of use and exceptional accuracy. 

Choose the right plasma cutter size

If the plasma cutter is unsuitable for your task, it may stop unexpectedly or falter. This can be due to the duty cycle being reached or the breaker tripping, resulting in frustrating interruptions and safety hazards. To avoid this, consider upgrading your plasma cutter. For more information, read our blog on how to choose a CNC plasma cutter.

Torch Height Control (THC)

Torch Height Control (THC) must be correctly calibrated before each job, selecting the right pierce height, cut height, and arc voltage settings according to the material type and thickness. Monitoring arc voltage during operation also helps to maintain the correct torch-to-material distance, reducing the risk of improper cutting or unsafe conditions. 

Regular maintenance of the torch height control is also critical, including inspecting THC components, replacing worn consumables, and ensuring smooth Z-axis movement of the torch. 

Use clean air

If the gas or air in your plasma cutter is unclean, it may cause missed or incomplete cuts. This can be frustrating, often leading to mistakes. Always ensure that the air or gas supply is free from moisture, oil, or contaminants and regularly inspect the air filtration system. 

How to choose a plasma cutting table

Wondering how to select the best CNC Plasma Table for your needs? In our helpful guide, you’ll find everything you need to choose the right plasma cutting table. 

• Safety features. 
• Cutting thickness requirements.
• Table and component size.
• Power requirements.
• Workload requirements.
• Our full range of plasma cutting packages.

Get your free downloadable copy by clicking below or try the Product Selector tool on our website to find your ideal solution.