Laser vs Plasma Cutting: What’s Best in 2024?

“Laser vs Plasma Cutting: Laser cutting provides precision and fine detail, ideal for thin metals. On the other hand, plasma cutting is faster and better for thicker materials.”

Laser and plasma cutting are the two methods of (CNC Cutting). They are used in many different industries and are helpful for electrically cutting a variety of materials. Though both processes share similarities, laser cutting, and plasma cutting have significant differences that we’ll explore in this article.

What is Laser Cutting, and How Does it Work?

Lasers have existed in everyone’s view for many years.  Laser cutting is really easy to handle. It is the form of light that is concentrated and focused. Light may be produced, determined, and directed in a number of ways—common lasers with different energy limits and usage, including CO2, Neodymium, and fibre laser technology. The Vulcan 20-20, which can produce a laser with 20 petawatts of electrical power, is now the strongest laser in the world. Basic weak lasers, about the dimension of a power source, are utilised for playing with cats. It is a tool for investigation rather than a cutting instrument.

Fiber or crystal laser-generating systems have laser cutting advantages and disadvantages in laser cutting. The majority of uses for these types of devices are limited to extremely particular situations or are scientifically tested, not routine industrial cutting and manufacturing. They typically need more advantages to offset the disadvantages and are bigger, more delicate, costly, intricate, and prone to failure.

When you acquire a laser cutting service, it’s usually a CO2 laser. These types of lasers use a tank that holds a combination of gases, such as nitrogen, helium, and CO2. A semiconductor device activates this gas combination, causing the molecules of carbon dioxide to get excited and release photons. When sufficient CO2 is present, this process produces many photons to form a cutting-capable, extremely energetic laser.

Laser cutting applications have increased because they are more accurate to adjust than plasma cutting and may be used for surface cutting, inscription, and other finishing operations. It is capable of cutting electrically conductive materials such as brass, aluminium, and steel. Still, it can also cut non-conductive materials such as silicon, wood, and porcelain. Additionally, it can cut metals like nickel and tungsten, which are more challenging to cut with plasma.

Types of Laser Cutting

The ability to cut lasers is used in various laser cutting materials, such as sheet wood, glass, metal, stone, and plastic, by several kinds of businesses. At the moment, laser cutting uses three primary types of lasers:

• CO2 Laser
• Fiber Laser
• Crystal Laser

Furthermore, various cutting techniques have been used to cut different kinds of materials. Among these techniques are the following ones:

• Vaporization Cutting
• Melt and Blow
• Thermal Stress Cracking
• Stealth Dicing of Silicon Wafer
• Reactive Cutting

Benefits of Laser Cutting

Large numbers of benefits are associated with laser cutting despite some laser cutting defects. As previously said, laser cutting is among the most, if not the most, practical techniques for manufacturers. What, therefore, causes this procedure to be so valuable to cutting businesses? Here are four factors that make it the most dependable technique for fabricating metal.

1. Precise Edge –Traditional cutting techniques, such as using a blade, can result in scratches or an uneven finish that needs to be softened and polished. When using lasers for cutting, this is not an issue.
2. Exact Detail—A laser beam never wears out, enhancing precision. Furthermore, the size of a standard laser and the fact that powerful machines control these devices make it feasible to construct complicated designs that would not be conceivable otherwise.
3. Low Maintenance—Standard cutting techniques call for regular blade maintenance and honing. This kind of upkeep is unnecessary for lasers, as they may operate for long periods between repairs.
4. Maximum Efficiency—Lasers don’t require adjustments or retooling, whether you are producing a large number of units or a prototype. This makes fabrication at its most efficient.
5. Variety of Uses – An extensive range of substances and densities may be cut with laser cutting.

6. Quick Setup—The preparation time for laser cutting is comparatively short compared to other metal cutting methods. Additionally, when bespoke manufacturing is required, modifications are significantly simpler to accomplish.

Quick Facts About Laser Cutting

• Over fifty years ago, laser cutting was first introduced.
• More than 25,000 uses exist for laser cutting.
• Cutting with a laser is very effective and safe for the environment.
• Most mild steels are cut using oxygen, which is less expensive than nitrogen.
• Gordon Gould created the term LASER, which stands for light enhancement by stimulated radiation emissions, in 1959.
• The accuracy of laser cutting is known to be extraordinarily high—up to a billionth of a meter.

What is Plasma Cutting, and How Does it Work?

Although plasma cutting looks like a cutting-edge technique, it was actually developed in 1957. Over the next sixty years, innovation has advanced significantly, especially in terms of plasma cutting capabilities and related areas such as computerized and mechanical controls.

Plasma cutting

How Laser and Plasma Cutting are Different?

Let’s begin by discussing the connection between laser and plasma cutting. The processes they apply for cutting materials are where they are most comparable. Both of them are known as “Thermal cutting” Techniques. In other words, they burn or dissolve the material by using the focussed heat, which produces a space that eventually turns into a cut. In comparison, gouges or frictions are more mechanical means of material removal.

Plasma and laser cutting are strong instruments and suitable for situations requiring accuracy. They are perfect for computer-assisted guiding, especially CNC cutting that has been designed. This explains how many complex, custom forms may be quickly cut from materials and how large quantities of repetitive production can be carried out.

Although they both function similarly and can achieve similar objectives, every strategy has unique advantages and disadvantages that may make one better under certain conditions. 

Let’s explore further!

Comparing Between Laser Cutting vs Plasma cutting Tools

Let’s review several factors and evaluate laser and plasma cutters about each axis.

Accuracy

Laser beams have a high degree of precision and focus. Because of this, they are often far more precise than plasma cutters, which have greater power and tend to be less concentrated. They could be more precise because plasma cutters usually leave a wider hole in the material and cut with a higher kerf.

Laser cutting precision

Compared to laser cutting machines, they produce greater dross and debris because they consume more material. Lasers are superior for sensitive and accurate work and non-cutting applications like inscription.

Flexibility

Something that catches photons may be cutting with laser cutters, a type of focused energy. Plasma cutters are limited to cutting materials that conduct electricity because they depend on the connection of electricity with the material. 

The drawback of laser cutters in this situation is that certain metals are highly reflective and catch very few if any, photons. As a result, cutting these materials with lasers is either highly challenging or impossible since the lasers are effectively bounced away from the substance. 

Plasma cutters outperform laser cutters when cutting thick materials. Most conventional laser cutters can only accurately, quickly, and efficiently cut objects up to 19 mm thick. In the meantime, materials that are as thick as 38 mm may be effortlessly sliced using plasma cutters.

Laser cutter

Nevertheless, more robust lasers are capable of far more. Some powerful lasers can cut through almost anything, regardless of thickness, and can even cut materials at a distance of more than a mile. These are useless; rather than being created as production tools, they have been designed as military armaments and scientific experimentation apparatus.

Plasma cutters and welders have the same fundamental architecture. Many sophisticated welding equipment can cut plasma by just flipping a switch. On the other hand, portable laser devices are nearly nonexistent, and robotic CNC machines tend to be used for laser cutting. 

Energy Efficiency

Lasers can cut a comparable amount of material more quickly and with less energy than other methods, making them an energy-efficient choice. 

The energy efficiency of the laser cutter

For this reason, many people believe that laser cutters are more environmentally friendly than plasma cutters.

Cost 

The most crucial difference between Laser cutting and Plasma cutting is cost.

In general, laser cutters are pricey. Straightforward, hobby-grade equipment with limited power can cost anywhere from $500 to $4,000, while industrial-grade laser-cutting systems can cost up to $200,000. The universe is also genuinely limitless; the enormous research laser requires billions.

Starting with a plasma cutter is less expensive. Entry-level handheld plasma-cutting devices can cost as low as $200 to $300. Much bigger systems involving commercial CNC machines can cost anywhere from $5,000 to $20,000. Additionally, at some point, the surrounding automation and other technology cost more than the plasma-cutting machine.

Despite their higher initial cost, laser cutters require less energy and have almost no consumables compared to plasma cutters. For equivalent cuts, plasma cutters need more energy and supplies for the flame and the gases that produce the plasma.

Safety

Safety can always be the priority while using high energy. High energy and heat are used during laser and plasma cutting to remove objects, which can cause hot metal or other substances to splatter, sparks to fly everywhere, and airborne odours from burning things. 

Safety during laser and plasma cutting

There are two ways that plasma cutting is inferior to laser cutting;

The primary reason is that your equipment releases argon, helium, nitrogen, or whatever gas into the environment in addition to the average emissions because it uses that protecting gas to make plasma. The production of high-energy plasma releases considerable amounts of radiation into the environment surrounding the application-cutting process. In addition, it can cause superficial skin burns that resemble sunburn and damage vision. This radiation can also damage neighbouring equipment and interact with magnetic communications.

Most of these risks are avoidable. The facility may be significantly safer if PPE is used correctly and adequate ventilation, fume extractors, downdraft tables, and other equipment are used. Furthermore, safety is increased when handed procedures are performed manually rather than by CNC and robotic equipment.it is necessary to shield and ventilate a workshop while operating a machine. 

Which One is Better: Laser Cutting vs Plasma Cutting?

Hence, Laser cutting and Plasma cutting are beneficial, so it’s difficult to say which is superior. Precision cutting and cutting non-conductive metal materials are two areas where laser cutting shines. Nevertheless, the initial cost is more, being unable to cut more extensive components can be a significant obstacle, and the absence of portable versatility makes it poorer for one-off work.

On the other hand, plasma cutting is less expensive and simpler to operate. It is also an entirely reasonable alternative to hire welders who are proficient in this technique. Although it can be automated, which poses a greater risk to the operator’s safety, its versatility and low cost make it perfect for small and medium-sized enterprises that do not require big fabrication banks.

The truth is that a lot relies on the material you must cut, how frequently you are required to cut, and whether you want extra capabilities like welding or engraving. To decide which is the best investment, all you have to do is assess your situation.

You may always contact one of our specialists if you need clarification! We’re ready to support you in your upcoming endeavor.

Ready to Choose the Right Cutting Tool?

Whether you want to learn about precision laser cutting or the versatile power of plasma, ProleanTech has the solutions you need. Check out our selection of state-of-the-art tools, or contact our professionals for tailored guidance.