Laser cutting or plasma cutting?

Two technologies compared for metal cutting

Laser cutting for metals
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Building Technologies

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May 23, 2025

Il laser cut and plasma cutting They are two widely used technologies for cutting metals, but they have different operating principles, performances and fields of application.
Here is a simple but detailed comparison:


How does it work?

Use a jet of high temperature ionized gas (plasma) to melt metal. Gas (air, nitrogen, argon) is blown at high speed through a nozzle, along with an electric current that creates the plasma arc.

Advantages:

  • Economic: it costs less than laser, especially for medium-high thicknesses.
  • Veloce: very fast on mild steel, stainless steel and aluminium.
  • Versatile: cuts conductive materials well even with surface coatings.
  • High thicknesses: excellent for sheet metal 6mm to over 50mm.

Disadvantages:

  • Average accuracy: the cut is less precise and has a wider kerf (cutting width).
  • Rough finish: post-cutting work is often required to finish.
  • Wider ZTA: the heat-affected zone is larger (more thermal stresses).

How does it work?

Un high power laser beam (CO₂, fiber or Nd:YAG) is focused on the material, melting or vaporizing it. The assist gas (oxygen or nitrogen) helps expel the molten material.

Advantages:

  • Extremely high precision: tight tolerances, ideal for complex geometries.
  • Clean and fine cut: often requires no additional processing.
  • Perfect for thin thicknesses: excellent on sheet metal up to 10-15 mm.
  • Easily automated: ideal for mass production.

Disadvantages:

  • Expensive: high initial investment and maintenance.
  • Less suitable for very large thicknesses (over 25-30 mm it may lose efficiency).
  • Limited to specific materials: on certain reflective metals (such as pure copper or aluminum) it may have problems.

In short: direct comparison

FeaturePlasma cuttingLaser cutting
Ideal SpessoreMedium-high (6–50+ mm)Thin-medium (0.5–20 mm)
PrecisionMediaHigh
FinishingRawClean, almost final
Speed ​​(high thicknesses)HighMedia
Machinery costLowerHigher
MaterialsConductive onlyAlmost all (but watch out for reflective ones)

Here is the summary diagram with a visual comparison between plasma cutting and laser cutting.

Laser Cutting vs Plasma Cutting Comparison

Which one to choose?

  • For heavy carpentry, high thicknesses and economical production → Plasma.
  • For precision work, design, small thicknesses, or artistic cuts → Laser.

We thank the company EFFE ELLE Srl and in particular Massimo for the support, the cutting samples, the photographs and the video of the processing.
www.effeelle.eu.com

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