Cutting Torch Vs Plasma Cutter

Cutting Torch Vs Plasma Cutter

Are you an industrial worker or DIY enthusiast faced with the question of whether to use a cutting torch or plasma cutter for your project? Whether you’re looking for precision, speed, or cost-effectiveness, you want the best tool for the job. In this article, we’ll explore the differences between cutting torches and plasma cutters, from cost to portability to safety. We’ll compare the pros and cons of each to help you make the best decision so you can get your project done right the first time. Join us as we explore the comparison of cutting torch vs plasma cutter.

Comparing Cutting Torch and Plasma Cutter

Cutting torches and plasma cutters are both essential tools in a wide range of projects, from professional welding to small-scale fabrication of simple objects. The best choice depends on the intended use, as both tools have their own unique benefits and drawbacks. In this section, we’ll compare the two sizes to provide insight into their pros and cons. We’ll look at cost, cut quality, durability, portability, and safety factors, to offer a comprehensive comparison and help you decide which tool is right for you.

What is a Cutting Torch?

A cutting torch is a tool that uses a combination of fuel and oxygen to create a powerful, high heat flame. The flame is used to cut through a wide variety of materials including metal, stone, and brick. The cutting torch is often referred to as an “oxy-fuel cutter,” as the flames are created by combining oxygen with a fuel such as acetylene, propane, or natural gas. The cutting torch usually consists of a torch handle, a fuel hose, and an oxygen hose, each of which is connected to the corresponding tanks.

The best way to use a cutting torch is with a “tip,” which helps to concentrate the flame and direct it more accurately. The size of the tip is determined by the thickness of the material being cut, with larger tips being used for thicker materials. The cutting torch also requires fuel pressure and oxygen pressure to be adjusted correctly – too much pressure can cause the torch to overheat and be dangerous, while too little can cause an inefficient cut.

What is a Plasma Cutter?

A plasma cutter is a tool used to cut through materials using an electrical arc. It works by sending a high-velocity plasma arc through a narrow opening in the electrode, creating a cutting current for the material being cut. The plasma is created using a compressed air source, usually from an air compressor or an air pump, which is fed through the electrode and compressed gas supply to generate the plasma arc. The cut is smooth, with almost no sparks and minimal heat input, making it ideal for a variety of projects. It is also generally easier to work with and more precise than a cutting torch, as it produces a thinner, more precise cut than a flame can.

Pros and Cons of a Cutting Torch

Pros of a Cutting Torch

  • Versatile – A cutting torch can be used to cut a wide range of materials.
  • Cost – Cutting torches are relatively inexpensive and have a long lifespan.
  • Low Investment – You only need to purchase a few accessories such as a fuel/oxygen hoses, torches, torch tips and a fuel such as propane.
  • Strong Cut – A cutting torch provides a powerful cutting capacity.

Cons of a Cutting Torch

  • Settings – It takes time to adjust settings for a clean and accurate cut.
  • Odor – Cutting torches produce a strong and unpleasant odor.
  • Inaccurate – Inexperienced users may find it difficult to cut precisely with a cutting torch.
  • Slow – Manual cutting with a cutting torch can be a slow process.

Cutting torches are an effective tool mainly used in industrial settings or by experienced users. They are inexpensive, but with a long learning curve when it comes to precise cutting. They can cut a variety of different materials, but produce strong odors, and a relatively slow cut. For small home projects and quick cuts, a cutting torch may not be the most practical tool.

Pros and Cons of a Plasma Cutter

Plasma cutters offer the benefits of higher precision and controlled cutting, faster and more accurate cuts, and low operating costs. The convenience of a plasma cutter comes with a higher price tag, however. Many plasma cutters, particularly high-end models, can cost over three times more than a comparable oxy-fuel cutting system.

– Offer higher precision and more controlled cutting
– Faster and more accurate cutting than oxy-fuel
– Low operating costs

– Typically more expensive than Oxy-fuel systems
– Can be difficult to use for thicker material
– Difficult to rely on for gouging applications

Cutting Torch vs. Plasma Cutter – Cost

Cutting torches tend to have a much lower upfront cost than plasma cutters. Cutting torches and associated accessories and materials can be bought in a kit that typically costs between $200 to $400 USD. On the other hand, plasma cutters are more expensive and cost anywhere from $600 to $2,000 USD depending on the type and size required. Generally, plasma cutters require additional costs for consumables such as hoses, power sources and compressed air.

Overall, cutting torches are a more affordable choice due to their lower upfront costs compared to plasma cutters. However, the cost savings from an upfront purchase of a cutting torch need to be weighed against the cost of operating the equipment, while a more expensive plasma cutter may have lower overall operating costs. In addition, the cost of replacement parts and accessories should be taken into account when selecting a tool.

Cutting Torch vs. Plasma Cutter – Cut Quality

Cutting torches are known to produce rougher, more uneven cuts with more heat input than plasma cutters. Additionally, when cutting thinner materials, the human factor can come into play, as the flame has to be adjusted frequently to create the required level of cut precision and accuracy.

In contrast, when using a plasma cutter, the cut is more precise, with the machine and its settings doing the most of the work. The plasma cutter’s arc is narrow and able to create intricate designs and thinner cuts with ease, resulting in less slag or burrs in the edge of the cut.

Overall, plasma cutters are preferred if cut quality is the most important factor. If you are looking for quick, accurate and clean cuts then a plasma cutter is an ideal choice. However, if cost is a major factor then a cutting torch may be the way to go.

Cutting Torch vs. Plasma Cutter – Durability

Cutting torches have a much longer lifespan than plasma cutters, generally lasting ten years or more due to their simple design and robust construction. Heavy metal frames and tanks are used to provide them with superior strength and durability. On the other hand, most plasma cutters have relatively short lifespans, usually three to five years, as the electronics and components are subject to greater wear and tear.

Both cutting torches and plasma cutters require regular maintenance to ensure regular output, however, the maintenance requirements for cutting torches can be more intensive. Cutting torches require frequent changing and adjustment of tip parts and fuel and oxygen lines, while plasma cutters require regular cleaning of the electrode and tip to prevent build up and maintain efficiency.

Overall, the durability of cutting torches tends to outweigh the durability of plasma cutters, however, when considering the overall maintenance costs, many users opt for a plasma cutter due to the reduced costs in terms of parts replacement and upkeep.

Cutting Torch vs. Plasma Cutter – Portability

When it comes to portability, plasma cutters are more convenient and less cumbersome compared to cutting torches. Cutting torches require access to an external fuel source and require a larger setup for proper operation, making them less suitable for on-site jobs. Plasma cutters, on the other hand, often come in smaller, more compact sizes and can operate off of a variety of power sources, making them easier to transport and use in a multitude of locations.

Cutting Torch vs. Plasma Cutter – Safety

Using cutting torches comes with the risk of severe burns and explosions due to flammable gasses and open flame used by the torch. Therefore, it is important to always wear protective clothing and fireproof gloves when working with torches. Always keep a fire extinguisher nearby.

Plasma cutters are safer to use due to their enclosed design and electrical current. There is still a risk of electric shock, however, so it is important to wear protective clothing, goggles, and gloves while using a plasma cutter. It is important to never touch the electrode and nozzle of the plasma cutter when it is turned on as they become extremely hot while in use. It is also important to use proper grounding techniques to reduce the risk of electric shock.

In terms of safety, it is important to consider that there are risks associated with both cutting torches and plasma cutters. It is important to always put safety first and follow safety precautions when working with either tool.

Overall Comparison – Cutting Torch vs. Plasma Cutter

When it comes to choosing between a cutting torch and a plasma cutter, there are many factors to consider. Depending on the job requirements, one tool may be more suited than the other. The following is a comparison of some important factors of the two tools:

  • Cost: Cutting torches are more affordable to buy, but plasma cutters often require fewer components, making them a cheaper choice in the long run.
  • Cut Quality: Plasma cutters create a more precise and accurate cut, with few burrs and less heat input.
  • Durability: Cutting torches have a longer lifespan and more strength than plasma cutters, but require more extensive maintenance.
  • Portability: Plasma cutters are small and lightweight and can be used with various power sources, while cutting torches require a more complex setup.
  • Safety: Both tools should always be used with proper grounding techniques and protective clothing during operation to reduce the risk of electric shock and explosion.

Overall, the choice between a cutting torch and a plasma cutter should depend on the job requirements and preferences. For some projects, a cutting torch is ideal due to its low cost and high strength. On the other hand, plasma cutters offer quick, precise cuts without having to spend too much.


What cuts better than a plasma cutter?

A band saw may be able to cut materials more precisely than a plasma cutter. A diamond-tipped saw can also be used to cut through hard materials in a precise manner.

What is the difference between a plasma cutter and a plasma torch?

A plasma cutter and a plasma torch are both devices that use plasma created by an electrical arc or spark to cut or shape metal. The primary difference between the two is the way in which the plasma is used. A plasma cutter uses the plasma to cut through metal, while a plasma torch uses the plasma to heat and shape metal.

Which is better plasma cutter or oxy acetylene?

It really depends on the job you need to do, as each cutting tool has different properties and parameters that make them better for certain purposes. Plasma cutters have a higher cutting speed, but can only cut thick materials. Oxy-Acetylene is better for finer cuts and for thinner materials, as it can cut curves faster than a plasma cutter. However, this kind of tool requires a higher level of skill to operate.

What are the cons of using a plasma cutter?

The potential drawbacks of using a plasma cutter include high operating costs, safety concerns, increased noise, and the need for special protection equipment. Operating costs are high due to the need for a dedicated air compressor and machine consumables. Safety concerns are warranted when cutting metals with higher melting points, such as aluminum, as the temperatures can reach 40,000 degrees Fahrenheit. In addition, the blast created when a plasma cutter is used is louder than other cutting methods and can be a nuisance. Finally, individuals operating the machine must always use special protective equipment, such as safety glasses, leather gloves, and a welding helmet, to protect their eyes, hands, and ears from the intense heat and noise.


To conclude, both cutting torches and plasma cutters are important tools with their own strengths and weaknesses. When deciding which one to choose, think about the cost, cut quality, durability, portability, and safety needed for the job. If you are budget and time conscious, a cutting torch will likely be the best choice for you. However, if you need a precise cut with minimal heat input, a plasma cutter would be the better choice. Ultimately, it is up to you to determine which tool is best suited for your project.