Choosing a cutting process

Every cutting process has particular benefits and shortcomings that you should take into account before deciding on a cutting method. Also keep in mind that a combination of processes may be best for a particular application.

	× Plasma	× Oxyfuel	× Laser	× Waterjet	× Other mechanical tools
	Best for cutting metal between 6 and 80 mm (1/4″ to 3″)	Best for cutting thick carbon steel	Best for thin materials or parts requiring very tight tolerances	Best if cutting thick material or a variety of materials, require precise cut quality, or cannot have a heat affected zone
Common attributes
Industrial cutting category	Thermal	Thermal Compare to plasma	Thermal Compare to plasma	Erosive	Mechanical
Types of materials	Most metals	Carbon steel	Range of materials	Nearly anything	Metal, wood, plastic
Material thickness	Up to 80 mm (3″)	50 mm (2″) and above with widest range of thicknesses	Typically 6 mm (1/4″) and below, but up to 30 mm (1.25") in some cases	Up to 305 mm (12″) and thicker with modifications to material support	Typically up to 25 mm (1″)
Cut quality	Very good	Very good	Excellent	Exceptional	Good
Speed when cutting ideal thickness	Fast	Fast (though requires pre-heat time)	Fast	Slow	Slow
Operating costs	$ - $$	$$	$$ (Higher for CO2 lasers)	$$$	$$$$
Capital equipment cost	$ - $$$	$	$$$$	$$$	$ - $$$$
Portability	X (air plasma only)	X	-	-	X
Heat affected zone	Larger	Larger	Smaller	None	Maybe
Safety enclosure required	No	No	Yes	No	No
Ability to cut rusty or painted material	Yes	Yes	With limitations	Yes	Yes
	Learn about plasma	Learn about oxyfuel	Learn about laser	Learn about waterjet