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ResourcesSheetLaser Cutting vs. Plasma Cutting: From Speed to Material to Cost

Laser Cutting vs. Plasma Cutting: From Speed to Material to Cost

picture of Kat de Naoum
Written by
 4 min read
Published November 18, 2022
Updated August 23, 2024

Which of these two processes is right for you? Read this article to find out.

Laser cutting machine - Image Credit: Shutterstock/Pixel B

Both laser and plasma cutting are computer numerical control (CNC) cutting processes. They’re useful for thermally cutting different types of materials and are used in many different industries. Although similar, they have a few important differences, which we’ll cover in this article.

What is Laser Cutting?

Laser cutting allows cuts through a material with a concentrated laser beam that melts and separates a local part of it. In most cases, the process will be accompanied by a gas that blows the melted material out of the way, or the freshly cut material will be turned from a solid to a gas (called sublimation), also getting it out of the way, but this time in vapor form. Laser cutting is quite versatile, as it can be used to cut structural and pipe materials, in addition to thin sheets.

There are three main types of lasers you can use for laser cutting—they all basically do the same thing, but some are better for thicker materials. They are CO2, neodymium, and fiber laser systems:

  • CO2 cutters, the most popular of the three, use electrically stimulated CO2. They’re versatile, inexpensive, and don’t need a lot of power. 
  • Neodymium cutters, also known as crystal laser cutters, use Nd: YVO (neodymium-doped yttrium ortho-vanadate) to produce the beam. 
  • Fiber cutters use fiberglass to cut through surfaces. Some special fibers are then used to amplify the seed laser, and this is what creates the final beam.

Laser cutting is used almost everywhere, from electronics to medicine, and aircraft to transportation. It’s also a great way to get precise cuts and finishes, and that’s why many Xometry customers opt for laser cutting when it comes to materials like tungsten, steel, aluminum, brass, and nickel. But it can also cut non-metals like silicon, wood, and ceramics. Here are what some laser-cut metals can look like:

laser-cut metal parts
Laser cut metal parts

What is Plasma Cutting?

Unlike laser cutting, plasma cutting forces a hot, electrically charged gas like argon or nitrogen through a small nozzle. It hits the surface with speed and high pressure, essentially melting and eroding the material as it passes through. The similarity, however, is that, like laser cutting, plasma cutting is a thermal cutting process because the plasma it forms can reach up to 20,000°C.

With plasma cutting, you can only use conductive metals like steel, stainless steel, and copper, because these complete the electrical circuit. That’s why most of our customers who use plasma cutters are often in sectors like auto repair and restoration, fabrication shops, and industrial construction. This diagram breaks down the plasma-cutting process:

plasma cutting process diagram
The process for plasma cutting

Comparing Laser Cutting vs. Plasma Cutting

The main area where these two cutting processes differ is their power source. Laser cutting machines cut through materials using a narrow and intense ray of light, but plasma cutters emit a directed flow of plasma instead. Both methods are mainly used to cut metals, but laser cutting can also be used for cutting other materials, like ceramic and wood. The below side-by-side comparison table offers a more in-depth look at their differences.

ComparisonLaser CuttingPlasma Cutting
Comparison
Accuracy
Laser Cutting
It’s more accurate than plasma cutting and concentrates on a tiny area. This makes its cuts smoother, too.
Plasma Cutting
It’s not as accurate as laser cutting and produces a larger seam and slightly rougher cuts which may need to be ground down.
Comparison
Speed
Laser Cutting
It’s faster and more energy efficient than plasma cutting.
Plasma Cutting
Plasma cutting takes longer than laser cutting.
Comparison
Materials
Laser Cutting
It can cut through various materials like metal, wood, ceramics, and plastics.
Plasma Cutting
It’s limited to conductive materials.
Comparison
Reflective material compatibility
Laser Cutting
Although it’s fine for a variety of materials, it’s not as good as plasma cutting for reflective materials like metal.
Plasma Cutting
It’s better at cutting reflective materials.
Comparison
Sheet thickness
Laser Cutting
It will struggle with anything thicker than 19mm but can cut 12.7mm thick aluminum, 19mm thick stainless steel, and 25.4mm thick steel.
Plasma Cutting
This can cut through metal sheets up to half an inch (38mm) thick.
Comparison
Cutting surface
Laser Cutting
The cutting surface is smooth, with good cut quality and no burrs — ideal for detailed designs.
Plasma Cutting
It’s known to have poor perpendicularity, making cuts with more cutting slag that needs to be removed by grinding.
Comparison
Slot widths
Laser Cutting
It makes cuts with very narrow slot widths of approximately ±0.15mm and high precision of 0.01mm or less.
Plasma Cutting
It has a larger slot width (larger than 3.8mm) and a precision of about 0.5–1mm.
Comparison
Cost
Laser Cutting
Laser cutters are generally way more expensive. In addition to the capital investment, they are usually more expensive to run, too.
Plasma Cutting
Plasma cutters are cheaper to buy and operate.
Comparison
Maintenance
Laser Cutting
Laser cutters normally need more maintenance.
Plasma Cutting
Less maintenance is needed compared to laser cutters.
Comparison
Kerf size
Laser Cutting
Laser cutters, being more precise, produce a small kerf (the size of the seam).
Plasma Cutting
Plasma cutters make a larger seam, or kerf, because they’re not as specific and precise.
Comparison
Radiation levels
Laser Cutting
Laser cutters don’t really produce any radiation.
Plasma Cutting
Plasma cutters actually create radiation, so they can be more dangerous. Wear protective equipment when using the machine.
Comparison
Additional functions
Laser Cutting
Laser cutters can usually also engrave.
Plasma Cutting
Plasma cutters can’t engrave, so they’re pretty much only used for cutting.

Laser Cutting vs. Plasma Cutting Comparisons

Greg Paulsen, the director of applications engineering here at Xometry advises, “For sheet cutting services, we almost always use lasers over plasma because of its superior detail resolution. Plasma cutting is lower cost, and works very well for items that you are welding together because you can sand or grind the edge condition.”

If, after reading this article, you decide that neither laser cutting nor plasma cutting is right for you, you can consider alternative methods like water jet cutting, oxy-fuel cutting, or wire EDM (electrical discharge machining).

How Xometry Can Help

Xometry provides a wide range of manufacturing capabilities, including sheet cutting and other value-added services for all of your prototyping and production needs. Want to learn more about our custom CNC cutting services, and get an instant quote? A Xometry representative is always available to help.

Disclaimer

The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry’s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.

picture of Kat de Naoum
Kat de Naoum
Kat de Naoum is a writer, author, editor, and content specialist from the UK with 20+ years of writing experience. Kat has experience writing for a variety of manufacturing and technical organizations and loves the world of engineering. Alongside writing, Kat was a paralegal for almost 10 years, seven of which were in ship finance. She has written for many publications, both print and online. Kat has a BA in English literature and philosophy, and an MA in creative writing from Kingston University.

Read more articles by Kat de Naoum

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