Posted on
18/02/2025
When it comes to high-precision cutting technology, two of the most widely used options are plasma cutters and laser cutters.
Both machines offer exceptional precision and automation, making them essential tools in metal fabrication and manufacturing. The question is — how do you choose the right CNC cutting machine for your application?
In this article, we compare these two popular cutting machines to help you make an informed decision. Whether you’re looking for the most cost-effective solution or the highest precision, this guide will help you find the best CNC plasma technology for your business needs.
CNC Machines — Laser cutting vs cutting with plasma cutter machines
CNC stands for Computer Numerical Control, referring to the computer software used to control the machine. Laser cutters and plasma cutters are two common examples of CNC machines, both used to cut metals with exceptionally high precision.
Both types of CNC machines have become indispensable tools, enabling automated tasks, increased efficiency, improved workplace safety, cutting precision, and consistency.
CNC plasma cutters
CNC plasma cutter machines use a high-powered plasma arc to cut electrically conductive materials such as mild steel, stainless steel, aluminium, brass, copper, cast iron, galvanised sheets, and more. Plasma cutting is highly versatile, as it does not require any special material preparation—workpieces can be oily, greasy, or rusty without significantly affecting the cut quality.
While there will always be a degree of edge bevel angle and some dross, these minor imperfections can be minimised with high-quality equipment and proper operator techniques. Plasma cutting is particularly effective for materials 5mm to 160mm thick, maintaining high efficiency and speed even as thickness increases. For materials above 10-15mm, plasma technology significantly outperforms laser cutting in terms of cost-effectiveness and cutting speed.
CNC Laser cutters
CNC laser cutting is commonly used for profile-cutting sheets of steel, using a highly focused laser beam to melt, burn, or vaporise material. Laser cutting is known for its superior precision, but it comes at a higher cost—especially for cutting steel thicker than 6mm. The efficiency of laser cutting drops significantly as material thickness increases, making it less suitable for thicker materials compared to plasma.
Laser cutting also requires clean, high-quality materials free from rust, labels, rolling defects, or surface grooves, as these factors can negatively impact cut quality. Additionally, cutting highly reflective materials like aluminium, brass, and copper can be challenging. While lasers excel at cutting thin sheets (0.5mm to 15mm) with high precision, achieving high speeds and accuracy requires expensive, high-quality drive and control systems.
It is also important to note that operating a fibre laser requires a high-quality safety enclosure in most cases to protect against reflective laser beams. Additionally, strict safety regulations vary by location, likely increasing handling costs.
Why choose plasma cutting over laser cutting?
The main reason for choosing plasma cutting is economical. Both the initial investment and ongoing operational costs are much lower for a plasma machine, making them a more viable investment. When we consider the relative cut precision and versatility, plasma machines are a superb all-round solution, offering a great combination of the following benefits:
- Can cut a wide range of material thickness
- Good cut quality
- Faster cut speeds
- Lower operating and maintenance costs
- Lower initial investment
In our experience, the only reason to opt for a laser machine is if you need an exceptionally high cut quality with no dross or edge bevel. In saying that, plasma cutters will still produce a precise cut, only with a small amount of dross on the edges.
In terms of affordability, although prices are significantly influenced by different cutting requirements, the investment costs for modern plasma cutting tables are in general significantly lower than laser cutting tables.
Plasma vs laser comparison
| Factor | Plasma cutting | Laser cutting |
|---|---|---|
| Material requirements | Low | High |
| Range of material thickness | Up to 160 mm | Up to 60 mm |
| Cutting speed < 10 mm | Slower | Faster |
| Cutting speed > 15 mm | Faster | Slower |
| Cut quality | High | Very high |
| Investment cost | Lower | High |
| Operating costs | Low | Low |
| Safety requirements | Low | High |
*Table based on Kjellberg study.
How to choose the right CNC plasma cutter
The best plasma cutter depends on the application, factoring in the workpiece materials, required table size, power requirements, software, durability, safety features, and more.
Or, to calculate how quickly you could pay your new machine off, try our Viability Calculator.
For more information on CNC plasma machines, download our free CNC Plasma Buyer’s Guide today. Inside, you’ll find everything you need to know about our CNC Plasma range, whether you’re purchasing for the first time or you’re looking to upgrade what you already have.
We’ve included all the details to help you make an informed decision, from product specifications and pricing to examples of our work. To get a free downloadable copy of the Buyer’s Guide, simply complete the form below.