For construction workers and many DIY enthusiasts and artists, a plasma cutter is a must tool to own. There was a time when plasma cutters were gigantic machines that were impractical for home use. But now with the advancement of technology they have become lighter and compact enough to keep in your garage.

When searching for a plasma cutter there is a wide range of options to choose from. Choosing the best one for your specific needs may require hours of research, web surfing and product evaluation. To spare you the trouble, we have done that for you and came up with a list of top performing plasma cutters you can buy online.

In this article, we have provided a sequence of best plasma cutters reviews. We have also added some tips and useful information to help you better understand how to pick the right plasma cutter that will properly fit your needs.

What Is The Best Plasma Cutter For The Money?

If you don’t have the time to go through the whole article then we would recommend you go for the Miller Electric Spectrum 625 X-treme. Yes, it is a bit expensive but it is very powerful and lightweight as well that justifies it’s high price. If you are looking for a professional-grade portable device then this is the best plasma cutter for you.

But we would recommend that you read through the whole article before making your decision.

Side By Side Comparison Of Our Top Picks

Best Overall
Preview
Plasma Cutter, Spectrum 625, 90PSI, 12ft.
Max Cutting Thickness
5/8 ”
Duty Cycle
50% @ 50A
Weight
21 lbs
Input Voltage
120-240 V
Average Rating
Number of Reviews
Check Price
Value For Money
Preview
Hobart AirForce 40i Plasma Cutter, Model:500576
Max Cutting Thickness
3/4 ”
Duty Cycle
50% @ 40A
Weight
31 lbs
Input Voltage
240 V
Average Rating
Number of Reviews
Check Price
Best Under 1000
Preview
Lotos LTP8000 80 A Plasma Cutter with Pilot Arc Metal Cutter 220~240V, 1 inch Clean Cut, Brown
Max Cutting Thickness
1"
Duty Cycle
60% @ 70A
Weight
38 lbs
Input Voltage
220-240 V
Average Rating
Number of Reviews
Check Price
Best Under 500
Preview
LOTOS LTP5000D 50Amp Non-Touch Pilot Arc Plasma Cutter, Dual Voltage 110V/220V, 1/2 Inch Clean Cut, Brown
Max Cutting Thickness
1/2 ”
Duty Cycle
60% @ 50A, 240V
Weight
20.9 lbs
Input Voltage
110-240 V
Average Rating
Number of Reviews
Check Price
Best Budget
Preview
Lotos LT3500 35 Amp Air Plasma Cutter, 2/5 Inch 10 mm Clean Cut, 110V/120V Input with Pre Installed Air Filter Regulator with NPT Quick Connector, Brown
Max Cutting Thickness
1/2 ”
Duty Cycle
35% @ 35A
Weight
17.6 lbs
Input Voltage
110 – 125 V
Average Rating
Number of Reviews
Check Price

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What Is A Plasma Cutter?

Before we jump into the “reviews” and “how to’s” it should be in your best interest to know what a plasma cutter is.

A plasma cutter is a device that uses high temperatures, electrical channels of ionized gas to cut through various types of metal. For example, steel, copper, brass, aluminum, etc. They can generate temperatures of up to 45,000 degrees Fahrenheit provided that they are supplied with enough power.

Plasma cutters are much safer and more efficient than alternative cutting methods. But they are quite expensive as well. Of course, they do pay off in the long run which makes them the best choice for anyone who needs metal cutting equipment.

Best Plasma Cutters For The Money Reviewed

We have divided this list into a few sub-sections. We have done this so that it is easier for you to choose the correct plasma cutter according to your budget.

1. Miller Electric Spectrum 625 X-treme

Miller Electric Spectrum 625 X-treme

 

If you are doing light construction work or just small DIY projects then the Miller Spectrum 625 X-treme is your go-to plasma cutter. It is quite lightweight at only 21 lbs. making it a highly flexible and portable plasma cutter that can be easily moved from one work site to another. Besides that, it is also very well built that allows it to withstand long hours of work.

This powerful and compact 40 amps plasma cutter can cut through 5/8-inch steel with ease with an IPM of 15. This is more than enough for most personal uses. It comes with a 3 years warranty.

Specification

  • Brand: Miller Electric
  • Model: Spectrum 625 X-treme
  • Input Voltage: 120 – 240 V
  • Rated Output Voltage: 140 VDC
  • Cutting speed: 15 IPM
  • Duty Cycle: 120V -20%, 240V -50%
  • Weight: 21 lbs.
  • Warranty: 3 years

Features

  • Great Cutting speed: The Miller Spectrum 645 X-treme offers 15 IPM of cutting speed that is sure to suffice for most home users and DIY enthusiasts.
  • XT40 torch: The XT40 torch comes with a unique handle with a no-slip grip, thumb guide, and finger contours to prevent slipping and provide maximum comfort of use. The 12 ft long cord adds an extra level of versatility that makes using the torch a breeze.
  • Auto line adapters: Auto-Line ensures flexibility to the end-user. The Auto Line circuitry allows automatic connections to 120–240 VAC, single-phase power, 50/60 Hertz, without the need for removing the covers for relinking the power source.
  • Miller X-Case: The X-Case provides plasma cutter protection during transport and storage.
Pros
  • Compact, portable and easy to use
  • Tough exterior that ensures longevity
  • Auto Line adapters
  • Long chord which is very convenient
  • Adequate cutting speed
Cons
  • Pigtail connectors are difficult to work with
  • Comes with a high price tag (totally justified though)

 

>>>Miller Spectrum 625 X-treme Review<<<

2. Hypertherm Powermax 45 XP Hand System

Hypertherm Powermax 45 XP Review

 

The Hypertherm Powermax 45 XP Hand System comes from an American brand and is made in New Hampshire. The machine is super durable and can withstand the harshest working environments. It can regulate air pressure automatically with its smart sense of technology that greatly elongates its lifetime.

The Hypertherm Powermax 45 XP is very small in size and quite lightweight. This makes transporting the plasma cutter a breeze. Its patented drag cutting technology ensures ease of use even for beginners.

The torch designed allows both handheld and mechanized operation and it supports a wide variety of consumables. This makes the Powermax 45 XP a truly versatile device.

Specification

  • Brand: Hypertherm
  • Model: Powermax 45 XP
  • Input Voltage: 200 – 240 V, 480 V
  • Output Range: 145 VDC
  • Cutting speed: 15 IPM
  • Duty Cycle:
    50% at 45 A, 200 – 240 V, 1-PH
    60% at 41 A, 200 – 240 V, 1-PH
    100% at 32 A, 200 – 240 V, 1-PH
    50% at 45 A, 480 V, 3-PH
    60% at 41 A, 480 V, 3-PH
    100% at 32 A, 480 V, 3-PH     
  • Weight: 35 lbs.
  • Warranty: 3 years (Power Supply), 1 Year (Torch)

Features

  • Super Compact: The Hypertherm Powermax 45 XP is very small in size and lightweight as well. This makes this plasma cutter great for projects where mobility is important.
  • Drag-Cutting technology: Their patented cutting technology makes the device easy to use even for beginners. So, this is a great device for individuals looking to learn using plasma cutters.
  • Smart Sense: The smart sensor technology automatically controls the air pressure to protect the device from malfunctioning and extend its lifetime.
Pros
  • Compact
  • Lightweight
  • Original drag cutting technology
  • Smart sense
  • Very versatile
  • Easy to learn
Cons
  • Comes with a high price tag

 

>>>Hypertherm Powermax 45 XP Review<<<

More on Hypertherm!

A step up but more costly version would be the Powermax 65. While a step down would be the Powermax 30, which have two variants –

  1. Powermax 30 Air – Comes with builtin Air Compressor
  2. Powermax 30 XP – Better choice if you hate dross and wide kerfs

Powermax 85 is an industrial grade option. Getting confused already? Check out our comparison!

3. Hobart Airforce 40i – Best Value For Money

Hobart AirForce 40i Plasma Cutter

 

Hobart is a company well known for their quality products among welders. And the Hobart Airforce 40i is an example of their reliability and quality. It is one of the company’s most powerful models. It promises fast and efficient cutting with incredible reliability at a compact form factor that makes this plasma cutter the perfect device for both personal and professional use.

It has a decent maximum cutting speed of 9 IPM on 5/8-inch-thick steel. At full bore, the device has a duty cycle of 50% that is no less than impressive. The Hobart Airforce 40i promises clean cuts with narrow kerf and minimum required clean up.

Specification

  • Brand: Hobart
  • Model: Airforce 40i
  • Input Voltage: 240 V
  • Output Range: 140 VDC
  • Cutting speed: 9 IPM
  • Duty Cycle: 240V -50%
  • Weight: 31 lbs.
  • Warranty: 5 years (Transformers), 3 years (Electronics), 1 year (Torch)

Features

  • XT40R Torch: The XT40R Torch lead is designed for increased ergonomics, trigger safety, more efficient cooling and cheap replacement cutting tips.
  • Pilot arc controller: This allows you to cut expanded or perforated metals and even painted or coated surfaces, without the need for retriggering the torch. This greatly reduces the hassle of cutting metal.
  • Fan-On-Demand: The cooling fans operate only when cooling is needed. This reduces power consumption and the number of contaminants drawn into the plasma cutter.
  • Post flow cooling circuit: The air plasma cutter enhances the durability of consumables and torch by cooling them with post flow air after releasing the trigger.
Pros
  • Compact
  • Lightweight
  • Ergonomic torch handle
  • Conservative power usage
  • Post flow cooling
  • Great duty cycle
Cons
  • Ground clamp is a bit weak

 

>>>Top 3 Hobert Airforce Plasma Cutters Reviews<<<

4. LOTOS LTP8000 Pilot Arch Plasma Cutter – Best Plasma Cutter Under $1000

Lotos LTP8000 80 A Plasma Cutter with Pilot Arc Metal Cutter

 

LOTOS is famous for its affordable products that are targeted toward DIY enthusiasts and small businesses. The LOTOS LPT8000 Pilot Arch Plasma Cutter is an affordable plasma cutter that does not lag behind the more expensive options by far.

Its pilot arch feature is of great use when trying to cut metal pieces with rough surfaces. It can cut through rough, painted and rusty metals with minimal slag. At 38 lbs. it is easy to move around. The two handles at the top of the device enhance its portability.

Specification

  • Brand: LOTOS
  • Model: LPT8000 Pilot Arch 80-amp
  • Input Voltage: 220240 V
  • Output Range: 40 – 80 A DC
  • Duty Cycle: 240V -60%
  • Weight: 38 lbs.
  • Warranty: 1 year

Features

  • Non-touch pilot arc: The pilot arc allows you to cut metals with rough or painted surfaces with ease. This feature allows you to cut with minimal slag which makes cutting easy and efficient.
  • PAPST cooling system: Using the PAPST advanced German cooling system, the LOTOS LTP8000 can achieve a 60% duty cycle at 80 A output & a 100% duty cycle at 60 A output. This means you can work for longer with little to no cooling time required.
Pros
  • Affordable
  • Compact
  • Lightweight
  • Non-touch pilot arc
  • Advanced German cooling system
  • Can easily cut rough and rusted metals
Cons
  • Comparatively short warranty

 

>>Top 8 Lotos Plasma Cutter Models Compared<<<

Honorable Mention: You may consider Forney Plasma Cutter – Good piece of machines in this price range.

5. LOTOS LTP5000D Non-Touch Pilot Arc – Best Plasma Cutter Under $500

LOTOS LTP5000D 50Amp Non-Touch Pilot Arc Plasma Cutter

 

The LOTOS LTP5000D is a light-duty plasma cutter for home users and DIY enthusiasts. It is like a slightly cut down version of the LTP8000. But LOTOS LTP5000D is no slouch. It is compact, lightweight, durable and comes with multiple useful and innovative features that make it an excellent choice for anyone looking to buy a plasma torch on a budget.

It has all the features we’ve previously discussed while reviewing the LOTOS LTP8000 at a much lower price. The only difference is that it has a maximum output of 50 amps DC and it is much lighter at 22.5 lbs. So, if you are looking for portability or just not interested in paying a premium for that extra power then the LOTOS LTP5000D is perfect for you.

Specification

  • Brand: LOTOS
  • Model: LPT5000D Pilot Arch 50-amp
  • Input Voltage: 110v 220 V
  • Rated Output Range: 10 – 50 A DC
  • Duty Cycle: 220V -60%
  • Weight: 20.9 lbs.
  • Warranty: 1 year

Features

  • Non-touch pilot arc: Just like the LTP8000 the pilot arc on the LTP5000D allows you to cut metals with rough, painted or rusty surfaces with ease. This feature allows you to cut with minimal slag which makes cutting easy and efficient.
  • Compact design: The LOTOS LTP5000D plasma cutter is super compact with a dimension of only 15 x 6 x 12 inches. It is also very lightweight at 22.5 lbs. This means it is easy to store and carry around making it great for jobs that require a portable device.
  • PAPST cooling system: Using the PAPST advanced German cooling system, the LOTOS LTP8000 can achieve a 60% duty cycle at 50 A output. This means you can work for longer with little to no cooling time required.
Pros
  • Cheap
  • Lightweight
  • Compact size
  • Effective cooling system
  • Can be used for painted and rusty metal
Cons
  • Short ground clamps
  • No PSI marking on the air regulator

 

>>>Lotos LTP5000D Review<<<

6. PRIMEWELD Premium Air Inverter Plasma Cutter

PrimeWeld 50A Air Inverter Plasma Cutter

 

The PRIMEWELD Premium Air Inverter Plasma Cutter is an affordable solution to your metal cutting needs. At 22.5 lbs. it is super light to carry around. Also, you are getting a highly reliable plasma torch with three years of warranty without paying for a premium.

This plasma torch is made in the USA and promises great durability that is reflected by their long warranty. Their digital inverter plasma system can cut through most metals of up to half-inch thick with pinpoint precision.

Specification

  • Brand: PRIMEWELD
  • Model: Premium and Rugged 50A Inverter plasma system
  • Input Voltage: 110v 220v
  • Rated Output current: 50 A DC
  • Weight:5 lbs.
  • Warranty: 3 years

Features

  • DC inverter: With its DC inverter technology this plasma cutter can easily convert DC to AC. This plays a part in the plasma cutter’s lightweight.
  • Dual Voltage: It supports dual voltages 110 V and 220 V. This means you can use this plasma cutter in various locations without the worry of carrying a converter.
  • Superior portability: Being super lightweight and small in size this plasma cutter can be easily carried around. This makes it an ideal plasma torch for job sites requiring you to be on the move.
Pros
  • Cheap
  • Very portable
  • Dual voltage
  • Precise cutting
  • DC inverter technology
  • Easy monitoring
  • Durable build
  • Easy to use
Cons
  • Short cord
  • The learning curve is a bit steep. So, not ideal for beginners

 

7. PRIMEWELD CT520DP Pilot Arc Plasma Cutter

PRIMEWELD CT520DP Pilot Arc Plasma Cutter

 

The PRIMEWELD CT520DP is an all in one versatile device that has multiple functions besides plasma cutting. This includes 200A TIG and Stick welding. So, you are getting a welding device and a plasma torch at the price of one. And a cheap price at that.

Besides the dual functions, the CT520DP has all other features you would expect from a plasma system of this price. It supports dual voltages which means it can be used without a converter in different locations. It is a bit heavy for a budget plasma cutter. But the weight is understandable as it is built for multipurpose use.

Specification

  • Brand: PRIMEWELD
  • Model: CT520DP
  • Input Voltage: 110v 220v
  • Rated Output current: 50 A DC
  • Cutting speed: 8 IPM
  • Weight: 32 lbs.
  • Warranty: 3 years

Features

  • Dual Voltage: You can connect this device to 110V or 220V outlets. As a result, this plasma cutter is easy to work within different locations without the need for carrying around a converter.
  • Multiple Functions: The CT520DP is a plasma cutter that can also do Stick and TIG welding. This means you do not have to carry around multiple devices. Instead, just the CT520DP alone will be enough to meet your needs.
  • 3-year warranty: A long warranty is not unusual for power tools. But for the price you are paying a 3-year warranty is impressive, to say the least.
Pros
  • Very affordable
  • Multiple functions
  • Dual voltage
  • Quite portable
  • 3-year warranty
Cons
  • Supplied cup size for the TIG is too small
  • Switching between plasma cutter and welder is difficult

 

>>>Primeweld CT520D Review<<<

8. HyperCut 40-AS Plasma Cutter

Hyperkion Plasma Cutter

 

The HyperCut 40-AS plasma cutter is an affordable option for your plasma cutting needs. It has a durable build and with 110 V input power, it can make precise and clean cuts. Its small size allows it to easily fit anywhere from your garage to the back of your truck. Built with IGBT technology the HyperCut 40-AS has great heat tolerance for the price.

So, if you are a DIY enthusiast or just need a portable plasma cutter for light-duty work then the HyperCut 40-AS plasma cutter would be a great choice.

Specification

  • Brand: PRIMEWELD
  • Model: HyperCut 40-AS
  • Input Voltage: 110V
  • Rated Output Range: 1040 A DC
  • Duty Cycle: 110 V – 45%
  • Weight: 19 lbs.
  • Warranty: 3 years

Features

  • PT 31 Torch: The torch design is precise and efficient that can cut through any conductive metal.
  • Super light: At less than 20 lbs. this plasma cutter is easy to carry around on hand.
  • Long cord: The torch comes with a 13 ft long cord that provides an extra level of flexibility of use.
Pros
  • Cheap
  • Super light
  • Long cord
  • Great for a DIY project
  • 3-year warranty
Cons
  • Short duty cycle

 

9. LOTOS LT3500 – Best Cheap Plasma Cutter

Lotos LT3500 35 Amp Air Plasma Cutter

 

The LOTOS LT3500 plasma cutter is the cheapest in this list. If you are on a tight budget then this is as low as it gets. But cheap doesn’t necessarily mean a bad product. The LOTOS LT3500 has adequate cut capacity for DIY enthusiasts and light users. It’s very lightweight and super compact making it the most portable plasma cutter in this list.

Specification

  • Brand: LOTOS
  • Model: LT3500
  • Input Voltage: 110V – 125V
  • Rated Output voltage: 100V
  • Duty Cycle: 125 V – 35%
  • Weight: 17.6 lbs.
  • Warranty: 1 year

Features

  • Lightweight: At 17.6 lbs. the LOTOS LT3500 is the lightest plasma cutter in this list. You can easily carry it around on hand.
  • Easy Setup: The plasma cutter is easy to setup. LOTOS ensures that you can set it up and start working within 1 minute.
  • Easy to connect: This plasma cutter needs only 110 V to run. This means it can easily connect to your wall outlet and does not need extra equipment to run which makes this plasma cutter perfect for home users.
Pros
  • Very cheap
  • Very light
  • Easy to use
  • Connects to the ordinary wall outlet
  • Great for home users
Cons
  • Not recommended for professional use
  • Short duty cycle

 

>>>Lotos LT3500 Review<<<

How To Choose The Perfect Plasma Cutter?

Before you go through the list of top plasma cutters reviews, you must know what to look for in a plasma cutter. There are various properties of a cutter that should be evaluated before making a purchase. And here they are –

Type

There are plasma cutters of all shapes, sizes, and levels of power in the market. So, choosing the right one depends on the nature of your work. Plasma cutters can cut through almost all kinds of metals. So, the material you work with is not important.

But what is important is determining the frequency at which you use the equipment, whether you are using it for professional or personal use and are you using it for cutting thick or thin metals. For occasional and light-duty use a fairly non-expensive plasma device will get the job done. But, for serious use, you should be checking out more advanced models. Also, if you plan on using the plasma cutter with a generator then you should check if the device can handle fluctuating power.

Rated Output

When using a plasma machine, the results will depend on the maximum power output. The higher the power output, the higher the generated temperature. This will result in cutting faster, easier and cleaner.

Cutting speed

The cutting speed of a plasma cutter is rated by IPM or inches per minute. This determines the speed at which a it can properly cut through a metal sheet of a certain thickness. Evaluating this is very important as a plasma cutting machine with a high IPM will greatly enhance your workflow.

Duty Cycle

This is another important property of a plasma machine you must check before buying. The duty cycle of a plasma cutting device determines how long the it can continuously run within ten minutes before overheating at a certain amount of supplied power.

For example, a duty cycle of 240V – 50% means the machine can run for 5 minutes at 240 volts continuously without overheating. After that, it needs 5 minutes to cool down before being used again.

best plasma cutter for the money

Precautions While Using A Plasma Cutter

While using power tools of any sort certain precautionary measures should be taken. Especially, for tools as dangerous as plasma cutters. One wrong step can cause dire consequences leading to injury and even death. Here are somethings that you should keep in mind while using a plasma machine to ensure maximum safety:

  1. Clear work area: Before hooking up your machine to a power outlet make sure you clear the work area of any non-working personnel. Mainly children and pets. Make sure there are no inflammable martial anywhere near while you are using the plasma cutter.
  2. Keep a fire extinguisher: Even after taking all possible precautionary measures, keep a fire extinguisher close by just in case. Accidents happen in the most unforeseen ways. So, keep a fire extinguisher close and ready to use if and when a fire breaks out.
  3. Prevent electrocution: Wear rubber gloves and boots or stand on a rubber matt. Make sure that your equipment is properly grounded. Ensure the working environment is dry.
  4. Check the wiring: Always check the wires for any rips or tears before using. Rats often chew wire exposing the inner fibers that can lead to cross-connections.
  5. Wear protective gear: Always wear protective gear while using the plasma machine. This includes safety goggles, rubber gloves, and boots, non-inflammable aprons, etc. Make sure you wear a gas mask as they protect you from all the toxic fumes created while burning metal.
  6. Store in a safe place: After you are done with your work store the plasma cutters in a dry place away from anyone’s reach.

Checkout this article to learn more about how to use a plasma machine.

Plasma Cutter vs Torch

Both plasma cutters and Oxy-fuel torches have their own set of advantages and disadvantages. Here, I will be talking about them thoroughly so that you understand why you might want to prefer one of them over the other.

Plasma Cutter

A plasma cutter is a cutting tool that uses high temperatures and electrical channels of ionized gas to cut through various types of metals. For example, steel, copper, brass, aluminum, etc. They use electricity and gas for cutting metal. Between the electrode and the nozzle there is a compartment where these elements are fused to form plasma.

Plasma is then flown through an orifice by air pressure, forming a concise highly pressurized flow that conducts electricity. Increase in supplied electricity produces more heat which also increases cutting capacity.

A standard hand held plasma cutter can cut through a maximum of one-inch thick metal. They are usually used for cutting or gouging metals. Compressed air and electricity are needed for running plasma cutters. This can be an issue when the job requires portability.

Of course, newer plasma cutters are much more compact and portable than older generations. Also, electrical power supply is not a problem on various job sites where welder or generators are used.

One of the plasma cutter’s best advantage is that it can cut non-ferrous metals. These include cast iron, aluminum and stainless steel. These materials are commonly used in various projects. Precision and speed of cutting are also important advantages. When using plasma cutters you can expect lesser slag and more precise cuts then torch.

When using plasma cutters, you do not need to preheat the metal. This saves you tons of time and decreases the complexity of your work. You can expect faster speeds and better efficiency when working with thinner metals in comparison to torches. When it comes to ease of use plasma cutters are better than oxy-fuel torches.

Oxy-fuel Torch

The best thing about torches is that for cutting thick metals and portability, they are much better than plasma cutters. Torches offer better versatility. They can be used for gouging, heating, welding, brazing and cutting. They have a cut capacity of six to twelve inches.

But there are oxy-fuel torches that are capable of cutting as high as or even beyond twenty inches thick metals. A torch is independent of a power source or gas. This is an advantage in scenarios when portability is needed for the job. Smaller torches weigh as low as 35 pounds which makes it easy to carry them around and cut steel on the go.

When using torches, you can only cut ferrous metals which can be a clear disadvantage. But, for steel of more than one-inch thickness, oxy-fuel systems can provide better cutting efficiency in comparison to portable plasma cutters.

Oxy-fuel systems also have some exclusive features. These include fusion heat treating, welding, heat shaping, soldering etc.

While using torches, the metal is required to be preheated. After that oxygen is pointed towards the metal, forming a chemical reaction between the oxygen and the metal that forms iron oxide. This is called slag. This slag is then removed by the flow of oxygen cutting the metal.

Final Verdict

For our pick of the top plasma cutting machine, we are choosing the Miller Electric Spectrum 625 X-treme. The number one reason we have picked this one as the best is its raw power.

This plasma cutter has an excellent cutting speed of 15 IPM that makes it perfect for advanced professional use. It is also very lightweight and does clean and precise cuts that completely justifies its high price.

So, we are at the end of our best plasma cutter reviews. I hope this guide was of help to you. Best of luck with your next project.

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One Comment

  1. All of these welding helmets are auto-darkening, which are our favorite type of welding helmet. Auto-darkening means that the lens does not have a fix shade and you can keep it on for different welding processes.

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