CNC plasma cutter – what can go wrong?

If you need an accurate cutting machine for metalwork, you might be considering a CNC plasma cutter. And, while there are many advantages to a CNC plasma machine, we understand that you also need to know the potential challenges they bring.

In this article, we outline the various challenges you could experience with a CNC plasma cutter. We also explore the various alternatives and solutions to help you determine the best setup for your needs.

What is a CNC plasma cutter?

A plasma cutter uses superheated plasma to accurately cut various metals, such as steel, aluminium, stainless, brass, and copper. A CNC plasma cutter is controlled by Computerised Numerical Control, achieving maximum accuracy and eliminating human error.

Key components include the CNC plasma table, plasma torch, and software. The table is the cutting surface where the workpiece is laid. Above this, a gantry holds the plasma torch and moves it around according to the directions of the computer software.

Key benefits of CNC plasma cutting include:

• Optimised safety
• Automation and precision
• Speed and efficiency
• Ease of use
• Versatility
• Can be more cost-effective

Common applications for CNC plasma cutting include manufacturing, construction, art and design, automotive, aerospace, and metal fabrication workshops. They can be used to cut
structural components, create intricate metal parts and shape steel and aluminium components.

Potential challenges when using the wrong CNC plasma cutter

While the advantages of CNC plasma cutting are clear, we also understand that you need to understand the potential risks involved too. If you use the wrong plasma cutter, power supply, or air supply, the following issues may arise.

Cut quality

Plasma always produces a small degree of edge bevel angle and dross, meaning the cut precision may be slightly lower than on a Waterjet or Laser machine.

Solution

Imperfections can be minimised with good Torch Height Control (THC) and correct operator techniques. It is also worth noting that plasma cutters are far more cost-effective than Waterjet and laser cutting, with more than enough accuracy for most industrial applications. For more information, check out our blog comparing plasma, Waterjet, and laser cutters.

Dross build-up

By using Insufficient or improper equipment, dross may start to build up at the top or bottom of the workpiece. This will be worsened by incorrect feed speed, distance, worn consumables, incorrect air pressure, and suboptimal plasma cutter settings.

Solution

You can minimise dross build-up by optimising the feed speed, distance, air pressure, settings, and machine parts. To ensure you use the right equipment and settings, speak with our experts today.

Incomplete cuts

When using a CNC plasma cutter, some parts of the cut may be missed or incomplete. This is generally caused by dirty air, excessive feed speed, or inadequate amperage.

Solution

You can reduce the risk of incomplete cuts by using cleaner air, appropriate feed speed, and suitable amperage. For tailored advice, ask our team which settings are right for your application.

Machine malfunctions

If the plasma cutter or power supply is not suitable for your task, it may stop operating without warning. This can be due to the duty cycle being reached or the breaker tripping, resulting in frustrating interruptions during the cutting process.

Solution

If you already have a plasma cutter, you may need to consider upgrading or switching to a new power supply. If you are interested in purchasing a plasma cutter, speak with our team to determine the right machine and power requirements for the job.

Poorly designed software

Some manufacturers cut corners when developing their software, resulting in inefficient programs that are difficult to use.

Solution

To ensure your plasma cutter always runs efficiently, consider upgrading to more reliable software. For example, every Surefire table comes with our SURECONTROL software, designed for ease of use and exceptional accuracy.

Our CNC plasma cutting range

XT series

Looking for an industrial plasma cutter or a commercial plasma cutter? The XT Series is a complete CNC package, including a plasma cutter, SURECONTROL software, and a full suite of accessories. We can customise your table to suit your application, enabling you to design and cut metal parts with ease.

The XT series features heavy-duty closed-loop technology, high-quality linear bearings, a PC trolley, a precision Z-axis, and impressive cutting capacity. We’ve also incorporated industry-leading torch height control (THC), a waterbed for maximum fume control, a precision helical rack, and more.

• XT30 MK3 — 1525 x 3050mm cutting area
• XT24 — 1220 x 2440mm cutting area
• XT12 — 1220 x 1220mm cutting area

KT series

The KT Series is best suited for hobbyists and small to medium workshops. This no-frills solution is complete with everything you need, including a plasma cutter, SURECONTROL software, and a full suite of accessories.

The KT series features a highly accurate pulley geared drive system, V-style adjustable roller bearings, fool-proof modularity, two emergency stop switches, and optional water trays for fume control. Powered by Hypertherm, the KT series can travel at speeds of up to 10,000mm per minute.

• KT12 — 1220 x 1220mm cutting area
• KT24 — 1220 x 2420mm cutting area

To decide which CNC plasma cutting machine is best for your purposes, use our virtual Product Selector. Simply answer a few questions about your work and we’ll let you know the best solution. Alternatively, get in touch with our team of experts today and we’d be happy to help.