When it comes to precision cutting in various industries, laser cutting and plasma cutting reign supreme as the fastest and most accurate cutting technologies. Each technique has its own strengths and weaknesses, making them suitable for different applications and materials. Understanding which materials both laser and plasma cutters can tackle can be useful when deciding which cutting system is best suited for your needs.
At Hornet, we are a plasma OEM that also distributes high-quality laser, welding, and metal forming products to cover all your needs. Let’s explore the different materials you can cut with laser and plasma cutters and learn how a machine from Hornet can help streamline your projects.
Which Materials Can You Cut with a Laser Cutter?
Innovative laser cutting technology offers unparalleled precision and speed to create intricate cuts on a wide range of materials. What makes laser cutting a popular choice for manufacturing is its exceptional versatility. At Hornet, we are proud to offer Bodor laser cutting systems built for precision, speed, and reliability. Bodor offers proprietary laser scanning technology that can cut thicker materials with no beam reflection.
While most cutting equipment is limited to what materials it can effectively and safely cut, laser cutters can be used to cut many different materials, such as the following:
Metal
Metal is most commonly associated with laser cutting. Most types of metal can be cleanly cut with lasers, including popular options like iron and steel. The type of laser cutter being used will dictate the thickness of the metal, with some machines capable of cutting thicknesses up to 30mm.
When determining which type of laser cutter is best for your application, consider the quality level you’re trying to achieve. Laser power, beam diameter, pulsation, light frequency, and focal depth all play a role in how well metal can be cut without distortion. The two methods most frequently used in metal laser cutting are reactive and fusion.
Plastic
Some plastic materials, such as polyester and polyimide, can be cut using a laser cutter, particularly a diode or CO2 laser. Other plastic materials, such as polycarbonate sheets, can also be cut but have their limitations. For example, polycarbonate can generally be cut at 1 mm max without distortion.
The type of plastic material chosen can make a significant difference in the outcome of your project. Transparent plastics, such as poly(methyl methacrylate) (PMMA), acrylic, and Lucite, can achieve a polished finish when laser cut as the edges melt in a way that looks purposeful.
Glass
Glass requires a more cautious approach when cutting due to its fragility, but the right laser cutter can help you achieve your goal. However, only an experienced operator should attempt to cut glass with a laser as the reflective properties of the material require the proper safety techniques and the use of powerful cooling systems.
As glass is extremely fragile, it is prone to cracking or shattering when exposed to any type of cutting tool. Intense lasers, such as CO2 lasers that emit high-energy beams, can quickly cut through glass and create clean, intricate cuts. Laser engraving tools can also be used to create a variety of decorative products.
What Materials Can’t Be Cut Using a Laser Cutter?
While laser cutters are highly versatile and can effectively cut dozens of materials, they are not suitable for certain applications. Laser-cutting technology should not be used on polyvinyl chloride (PVC), epoxy, high-density polyethylene (HDPE), fiberglass, oily or resinous woods, and thick polycarbonate.
Which Materials Can You Cut with a Plasma Cutter?
In areas where laser cutters lack, plasma cutters deliver the power needed to cut through tough materials with ease. The biggest difference between the two machines is that while laser cutters offer greater versatility in the materials they can cut, plasma cutters can only cut electrically conductive metals. Hornet is a leading manufacturer of high-performance CNC plasma cutters. Our cutting systems can cut mild steel plates up to 3” thick, aluminum up to 3” thick, and stainless steel up to 4” thick.
Plasma cutters rely on creating an electrical arc, so only metals that conduct electricity can be effectively cut. Examples include:
Mild Steel
Mild steel is often favored for manufacturing projects due to its widespread availability. Alternative metals may not be as widely available or can be costly to purchase in large quantities, making mild steel a more attractive alternative. It’s also a very strong and versatile material that can be cleanly cut with plasma-cutting technology.
Plasma cutters can effectively cut through mild steel up to one inch thick. Plasma-cut mild steel is often used in the manufacturing of many steel products, such as rail cars, tanks, and other heavy equipment. The unique properties of mild steel allow electrical current to travel through without distortion.
Stainless Steel
As one of the most corrosion-resistant materials currently on the market, stainless steel is used for a wide range of manufacturing applications. It’s also a great option for plasma cutting due to its high strength-to-weight ratio, making it suitable for industrial applications and other high-production needs.
Plasma cutters can cut both thin and thick pieces of stainless steel. However, to achieve optimal cutting results, it’s important to set up the machine to accommodate the type of metal being cut. For example, stainless steel requires a different gas mixture compared to mild steel and other metals.
Aluminum
While aluminum may be a soft metal that poses a higher risk of distortion, plasma cutters can cut it with precision. However, some special precautions must be taken when cutting aluminum to achieve the desired output. The speed must be adjusted, and the appropriate gas taken into account.
Aluminum is commonly used in automotive and aerospace applications. It has the lowest melting point of any metal, making it easy to cut through it using a plasma cutter. It also works well in many architectural projects due to its low thermal expansion and high reflexivity.
Brass
Brass is often used in decorative applications such as picture frames, door handles, light fixtures, and decorative hardware. Its corrosion resistance, workability, and attractive golden appearance make it a popular material for both interior and exterior design elements.
As a highly conductive material, brass cuts easily with plasma. Similar to other metals, the proper gas settings must be taken into account based on the thickness of the brass. When safety protocols are taken, you can cut metal from thicknesses ranging from 30 gauge to one inch.
Copper
Copper is an electrically conductive material, meaning it can be cut with a plasma cutter. However, achieving a clean cut on copper can be challenging and requires specific settings to avoid issues such as arc deflection, which could ultimately impact your cut quality.
Plasma cutters work on copper but in a different way than they do on steel and similar materials. With metals like steel, the cut is vaporized and oxidized into fine dust. Copper reacts differently in that it doesn’t vaporize and requires considerably more power to cut and weld.
Titanium
Titanium is a commonly used metal recognized for its high strength-to-weight ratio and low density. It is often used as an alloying agent with other metals, such as iron, aluminum, and molybdenum. These types of alloys are primarily used in aircraft, missiles, and spacecraft as they can withstand extreme temperatures.
With the appropriate settings and a suitable plasma-cutting machine, titanium can be cut using plasma technology. Careful control of cutting parameters is required due to the metal’s reactivity. Specialized safety and equipment are needed, and precautions should be taken to remain protected when cutting titanium.
What Materials Can’t Be Cut Using a Plasma Cutter?
While plasma cutting is an excellent solution for cutting a range of electrically conductive metals, it is not suitable for all applications. Plasma cutters can not cut any non-conductive materials, such as wood, plastics, or glass. It is also not suitable for poorly conductive metals, such as lead, manganese, tin, and tungsten.
Contact Hornet for a Quote on Your Next Cutting Machine
Manufactured in Valley Center, Kansas, and distributed around the world, Hornet produces 100% American-made cutting machines designed to assist fabricators across all industries. Whether you’re interested in a leading Bodor laser cutter or want to upgrade your old CNC plasma machine, we offer both new and used cutting tables at an affordable price. Contact Hornet Cutting Systems at 1-844-209-5552 to get started.
