Choosing the right cutting method can make a significant difference to the accuracy, finish and cost of a metal component. Laser cutting and plasma cutting are both widely used in metal fabrication, but each has its own strengths.
At Cutting Edge Laser, our new 30kW laser cutting technology takes precision and capability to another level, allowing us to cut much thicker materials with laser accuracy. It also enables us to produce holes with diameters smaller than the thickness of the material, with minimal deflection. For example, we can now cut 15mm diameter holes into 50mm thick plate, opening up new possibilities for components that require both substantial material thickness and exceptional precision.
Understanding how laser and plasma cutting differ can help you select the most suitable process for your material, design and production requirements.
What is laser cutting?
Laser cutting uses a highly concentrated beam of light to cut through material. The energy from the beam melts or vaporises the metal along a defined path, producing precise cuts and intricate shapes.
The process is particularly useful for components that require tight tolerances, detailed profiles or a clean finish. Modern laser cutting systems can also process a wide range of designs efficiently, making them suitable for both individual components and repeat production runs.
With our new 30kW laser, Cutting Edge Laser can extend these advantages to much thicker plate, combining the ability to process substantial material thicknesses with the accuracy and detail associated with laser cutting.
What is plasma cutting?
Plasma cutting uses an electrically conductive, ionised gas to generate a high-temperature arc that melts metal. The molten material is expelled from the cut by the gas stream.
It is commonly used to cut conductive metals, including steel, stainless steel and aluminium. Plasma cutting is particularly effective for thicker plate and larger components where extreme precision or intricate detailing may be less important.
The benefits of laser cutting
1. Greater precision and accuracy
One of the main advantages of laser cutting is its ability to produce accurate components with intricate profiles and fine details.
The narrow cut width allows for precise shapes, smaller features and carefully positioned holes. This is particularly valuable when components need to fit together accurately during assembly or meet specific engineering tolerances.
Our new 30kW laser further extends these capabilities by allowing us to cut much thicker plate while maintaining laser accuracy. It also gives us the ability to produce holes with diameters significantly smaller than the material thickness, with minimal deflection.
For example, we can now cut 15mm diameter holes into 50mm thick plate. This is a significant advantage for applications where smaller holes would traditionally be difficult to achieve accurately in thick material, potentially reducing the need for additional machining operations.
2. Cleaner edges and less finishing
Laser cutting can produce smooth edges with a relatively small heat-affected zone. Depending on the material, thickness and cutting parameters, this can reduce the amount of grinding or other finishing required after cutting.
Reducing secondary operations can help simplify production and shorten the time between cutting and the next manufacturing stage.
3. Complex designs and intricate shapes
Laser cutting is well suited to components with detailed profiles, small features and complex geometries.
Because the cutting path is controlled digitally, designs can be translated into repeatable cuts without the need for dedicated physical tooling for each shape. This makes laser cutting a flexible option for bespoke components as well as repeat orders.
The increased power of our 30kW laser also allows us to combine complex cutting requirements with much thicker materials, giving customers greater flexibility when designing components that need both strength and precision.
4. Consistency across production runs
Once the cutting programme and process parameters have been established, laser cutting can reproduce components consistently across a production run.
This repeatability is particularly useful when manufacturing multiple identical parts or components that need to fit into a larger assembly. It can also help reduce variation and avoid unnecessary rework.
5. Efficient use of material
Laser cutting software can arrange components on a sheet or plate to make efficient use of the available material. This process, known as nesting, can help reduce scrap and improve material utilisation.
The narrow cut width can also be an advantage when working with closely spaced features. Actual material savings depend on the component design, material dimensions and production requirements.
Laser cutting vs plasma cutting: Key differences
| Consideration | Laser cutting | Plasma cutting |
| Precision | Generally offers higher precision, including on thick plate with suitable high-power equipment | Generally offers lower precision |
| Intricate designs | Well suited to fine detail and complex profiles | Better suited to less intricate profiles |
| Hole quality | Often preferable for smaller, accurately sized holes; our 30kW laser can cut 15mm diameter holes in 50mm thick plate with minimal deflection | Hole quality can become more challenging as thickness increases relative to hole diameter |
| Edge finish | Typically produces a cleaner edge | May require more secondary finishing |
| Material thickness | Depends on laser power, material and machine capability; our 30kW laser allows us to cut much thicker materials with laser accuracy | Particularly useful for thicker conductive metals |
| Cost | Often advantageous for precision components and reduced finishing | Can be economical for heavy plate and simpler parts |
How to choose the right cutting method
Before deciding between laser and plasma cutting, consider the following:
- Material and thickness: Check which processes can cut the material reliably at the required thickness.
- Component design: Small holes, intricate profiles and tight tolerances may favour laser cutting. Our 30kW laser is particularly advantageous when these features are required in thick plate.
- Required finish: Consider how much additional grinding, deburring or machining will be acceptable.
- Production volume: Repeatability, cutting time and material utilisation can all affect the overall cost.
- Total project cost: Compare the complete manufacturing process, including finishing and any additional operations, rather than looking at cutting costs alone.
Choosing the right process for your project
Laser and plasma cutting each have a role in modern metal fabrication. Laser cutting is often the preferred option when accuracy, intricate detail and edge quality are priorities, while plasma cutting can be a practical solution for thicker plate and less complex components.
Advances in high-power laser technology are also changing what is possible when cutting thick materials. At Cutting Edge Laser, our new 30kW laser allows us to combine the ability to cut much thicker plate with the precision needed for demanding features, including 15mm diameter holes in 50mm thick material with minimal deflection.
The most suitable method will depend on the demands of the finished part, not simply the cutting technology itself.
At Cutting Edge Laser, we can help you assess your requirements and identify a suitable approach for your components. Get in touch with our team to discuss your next project.