Metal fabrication instructors talk about advantages of Powermax SYNC plasma cutters

Two U.S. high schools offer specialized programs focusing on different aspects of agriculture, such as agriculture mechanics, agriculture science, and applied agriculture and engineering. Metal fabrication is part of their curricula, and making plasma cutting easy to learn and do is a key goal for the metal fabrication teachers.

Challenge: Making plasma cutting easy to learn   

Teaching high school students how to use a plasma cutting system can be challenging. Learning how to accurately determine which consumables need to be replaced is not easy, and correctly reinstalling consumables can take time to learn. High schools also have limited budgets, so avoiding costly consumable mistakes and extending consumable life are essential. For students, having better cut quality means less time spent on secondary work. This is critical, since students have other classes and commitments and cannot devote all their time to fixing poor quality cuts.

Solution: Powermax SYNC delivers easy-to-use, high-quality performance

Both school systems chose the Powermax SYNC^® because the system is easy to learn, delivers high cut quality, and is cost effective to use. Its single-piece cartridge consumable lasts two to three times longer than traditional consumables, and combining five consumables into one cartridge makes consumable management easy for new students.

The Powermax SYNC

The Powermax SYNC is a next-generation, professional-grade air plasma cutter that dramatically simplifies system operation for gouging and cutting. It features automated system process setup via advanced RFID-enabled SmartSYNC® torches and a revolutionary single-piece cartridge consumable that provides trackable utilization data. The Powermax SYNC simplifies system operation, streamlines consumable inventory, lowers operating costs, and maximizes performance.

Benefits include:

• RFID-enabled SmartSYNC torches and cartridges automatically set the correct amperage and operating mode, eliminating setup errors.

• Easy-to-identify single-piece cartridge consumables are color-coded by process to eliminate parts confusion and simplify consumable inventory management.

• End-of-life consumable detection eliminates the uncertainty of knowing when to change the cartridge.

• Simplified system operation minimizes the time and costs spent on training and troubleshooting.

• Easily interchangeable torch styles and application-specific cartridges for various types of cutting and gouging enable operators to tackle a wide range of jobs.

• Time-saving hand torch controls allow the operator to adjust the amperage on the fly and change cartridges and applications without returning to the power supply.

• SpringStart™ technology ensures consistent starting and a more reliable torch.

Hypertherm Cartridge Consumables

Hypertherm’s cartridge consumables for Powermax systems change the plasma cutting process, making consumable handling, changing, and inventory management easy. The cartridge combines a traditional five-piece stackup into a single-piece cartridge, making change-outs faster, ordering easier, and inventory tracking simpler. Operators simply select the right cartridge for the job, and with a simple twist onto the torch they are ready to go.

Cartridges are easy to identify. They are color coded by application – green for gouging, yellow for drag cutting, etc. – and laser marked for easy identification of process and amperage. As a result, consumable change-outs take seconds, not minutes, reducing downtime and increasing productivity. Consumable mix-ups are also eliminated.

Cartridge consumables wear at the same rate, eliminating costs associated with premature disposal of consumable parts. Operators do not have to constantly uninstall, inspect, and reinstall consumables that wear at different rates.

Optimized cartridge consumable design means cartridge consumables last up to twice as long as standard consumables for handheld cutting, decreasing consumable costs and increasing productivity. Cartridge usage data provides valuable insights for improving cutting operations and consumable inventory management, increasing productivity even more.

The Powermax SYNC’s data collection feature keeps track of system performance data, including the number of starts, transfers, and total arc time. This information can be used to determine how much life is left in each cartridge.

Student impact: Easy to learn and use system enables success

“I like the Hypertherm system, period. I used the number one competitor against them for years, and I was having trouble with it. I finally switched over to Hypertherm. The Powermax is probably one of the best systems around.” – Jeff Sockwell, Agriculture Science Teacher

The Powermax SYNC benefits the teachers’ programs in several ways. The teachers love the system for its simplicity. The Powermax SYNC’s single-piece cartridge makes it easier for students to learn, and students can easily change processes as they complete their jobs. Students avoid consumable loading mistakes, with quicker part change-outs.

“The best part is its simplicity. It is really simple for students to learn and make changes as they go along with their job. With being able to interchange the different cartridges from either running a straight flat cut, to a gouge cut, to even a mechanized cut, students are able to work more effectively and efficiently.”  – Jay Trees, Teacher, Judson HS

The Powermax SYNC also has better cut quality, with less dross. This ensures students don’t have to spend as much time on secondary operations to fix poor quality cuts.

Cartridge consumables last up to twice as long as standard consumables for handheld cutting, decreasing consumable costs.

“It’s going to save us a lot of money in the end, because that life in the cartridge is going to way outlast having five different consumables that you have to use with just a regular plasma cutter.” – Jay Trees, Teacher, Judson HS 

Additional savings are realized because of the Powermax SYNC’s data collection feature. The students and teachers can now estimate how much life is left in a cartridge based on data, so they have a better idea when it is time to check cartridge health without just guessing.

“The other cool thing about the SYNC system is, I can sync it with my phone and it tells me how much estimated time I have left in the cartridge, and that makes it so much more cost efficient. On the old system, it was just a wild guess.” – Jeff Sockwell, Agriculture Science Teacher

The Powermax SYNC has benefitted both schools and their students. It’s easier to use than other plasma cutting systems and enables students to focus more on the work and less on how to use the machine.

Learn how the Powermax SYNC delivers better cut quality and longer consumable life. Click the button below, fill out the form, and a Hypertherm product expert will contact you.