If you don’t know what X-Definition plasma can do, you may be leaving money on the table

It’s been one year since the introduction of X-Definition^® class plasma, and during that time the technology, exclusively found in Hypertherm’s XPR^®, has been demonstrated at countless venues – from trade shows and open houses to events hosted by cutting machine manufacturers and integrators.

A characteristic response from many of those seeing the XPR in action is, “I didn’t know plasma could cut like that.” Interestingly, this comment often comes from a seasoned fabricator with one or more laser systems in their shop or someone about ready to purchase a new laser system.

In more than a few instances, this realization saved a fabricator hundreds of thousands of dollars in initial capital costs and ongoing operating costs when they decided to purchase a high-end cutting machine equipped with X-Definition, XPR plasma instead of a new laser system.

Modern vs. conventional plasma: no comparison

There are several reasons why so many people are surprised by the edge quality and fine feature capability that modern X-Definition plasma can deliver. First and foremost, they may never have seen a modern system perform on a modern cutting machine capable of precise motion.

Plasma systems and the cutting machines they operate on are, as a rule, industrially robust. It isn’t unusual to come across installations made 10, 15, or even 20 years ago. The people who are shocked by the XPR’s cut quality are using plasma systems from three generations ago as their point of reference.

Comparing an older, conventional plasma system – even if it is well maintained (which isn’t always the case) – with the X-Definition class plasma of an XPR system is like comparing the handling of a 1980s family minivan with a modern, high-end sports sedan. There is no comparison.

Even if someone has seen a recent high-definition system, its performance may have been suboptimal. The cutting machine may not have the right motion and/or deceleration-acceleration characteristics, or its performance may have degraded due to a lack of proper maintenance or ongoing training.

Plasma systems and the cutting machines they operate on are robust and fairly low maintenance industrial tools, but they are not maintenance free. No industrial tool is. Degradation is slow, and people may not even notice that the cut quality they saw when the system was new is a far cry from what they are getting now.

Desired cutting results at lower costs

Unfortunately, as mentioned at the outset, not being fully aware of what the latest technology can deliver may cost a fabricator a lot of money in both upfront and ongoing operating costs. Laser cutting plays an important role in modern metal fabrication, and there are certainly applications where it is the preferred cutting method. However, there are many plate applications in which a lower-cost plasma solution, especially in light of recent technological breakthroughs, is more than capable of producing the desired results – at a cost that is substantially lower.

X-Definition plasma cutting

X-Definition plasma delivers a step-change difference in plasma cutting performance, even compared with the recent generation of high-definition plasma cutting systems.

• In tests comparing plasma and fiber laser, X-Definition plasma showed less average edge deviation from perpendicular and slightly lower variability in deviation on mild steel 6 mm thick – even after 1,000 starts. The results were similar on 12 mm thick mild steel.

• Historically, operators had difficulty achieving good hole quality directly off the plasma cutting table, often requiring drilling as a secondary process. True Hole® technology using an X-Definition plasma process on the XPR virtually eliminates hole taper and improves hole roundness, producing bolt-ready holes that require no secondary process.

• X-Definition plasma also delivers better results on different thicknesses of stainless steel.

  • For thinner stainless steel up to about 10 mm, X-Definition plasma delivers parts that are typically in ISO range 2 or 3. These parts have a smooth surface finish, a neutral/shiny color, and essentially no dross.

  • On thicker stainless steel, X-Definition plasma produces cuts that are typically in ISO range 3 or 4, with bright, smooth edge finishes, no dross, and good perpendicularity.

• Using the X-Definition process Vented Water Injection™ (VWI), the XPR300® can generate ISO range 3 to 4 results on aluminum, with exceptionally smooth cut surfaces, low angularity, and no dross.

XPR plasma cutting systems

The XPR represents a significant advancement in mechanized plasma cutting technology, redefining what plasma can do by expanding its capabilities and opportunities in ways never before possible. It blends new technology with refined processes for next-generation, X-Definition cutting that delivers unmatched cut quality on mild steel, stainless steel, and aluminum.

The XPR also delivers increased cut speed, dramatically improved productivity and a significant reduction in operating costs. In addition, new ease-of-use features and engineered system optimization make the system easier to run with minimal operator intervention, while also ensuring optimal performance and reliability.

Training is faster, and seasoned operators deliver better cut quality more efficiently. Fast cutting speeds and consistent high-quality outcomes reduce labor requirements.

Sensors in the power supply deliver refined diagnostic codes and enhanced system monitoring information to reduce troubleshooting time and provide proactive system maintenance data for improved system optimization. These enhancements eliminate the impact of ramp down errors, increase consumable life, and reduce the impact of catastrophic electrode blowouts which can damage the torch at high current levels.

Machines equipped with an XPR X-Definition plasma system have access to Hypertherm’s exclusive  SureCut™ technologies. SureCut technologies are designed to maximize cutting performance by automatically applying optimized cutting process parameters to simplify cutting, improve cutting outcomes, and reduce operator intervention.

SureCut technologies include:

• True Hole® technology applies process expertise to automatically deliver bolt-ready holes.

• True Bevel™ technology automatically applies the correct bevel angle and reduces operator trial and error.

• Rapid Part™ technology increases the number of parts produced per hour by automatically reducing cut-to-cut cycle time between parts.

• PlateSaver™ technology combines XPR arc stability and specialized software parameters to dramatically increase material utilization.

 

Are you ready to see what today’s X-Definition plasma can do? If so, contact us today.

 

Editors note: This is the first article in a three-part series.

Read part 2