Cutting is one of the most essential functions of metal fabrication, allowing sheets of metal to be turned into all kinds of products. There are many types of metal cutting machinery, including plasma and laser cutters, each with its own pros and cons. It’s essential to choose the right cutting method to ensure efficiency, cost effectiveness, and precision.

At Sanson Machinery, we want our customers to have the tools they need to make informed decisions about what equipment to invest in. That’s why we’re presenting this helpful guide, aiming to help you understand the key differences between plasma and laser cutters.

The Basics of Plasma and Laser Cutters

First, let’s go over the basics of both plasma and laser cutters, exploring how they work.

Plasma cutters use an electrical arc and compressed gas to ionize the air and create plasma. Plasma is an ionized gas, which means it contains a mixture of both positively charged ions and negatively charged electrons. These machines cut through conductive metals by melting and blowing away material

Laser cutters, on the other hand, use a high-powered laser beam — often a CO2 or fiber laser. Similar to plasma cutting, they create cuts by focusing intense heat on a small area to vaporize or melt the metal. 

Plasma vs. Laser Cutters: Things to Consider

If you’re planning to invest in new metalworking machinery, it’s important to consider all factors that affect how it operates. From cut quality and speed to cost and safety, make sure you take into account all the differences between plasma and laser cutters. 

Material Compatibility

Plasma cutters are best for carbon steel, stainless steel, and aluminum, typically handling thicker metals of 2 inches or more. If you mostly work with thin- to medium-thickness sheets of stainless steel, aluminum, brass, or copper, a laser cutter may be best for you, as they can cut thin materials with extreme precision. 

Cut Quality and Precision

Laser cutters are generally more precise than plasma cutters, with narrower kerfs and minimal dross. They’re better for parts that require tight tolerances or detailed designs. Plasma cutters create cuts that are clean enough for structural applications, but may require post-processing like grinding or sanding. 

Cutting Speed and Efficiency

If you’re working with thicker materials, plasma cutters are faster. They’re good for general fabrication and quick production runs. For thinner materials, laser cutters are ideal; however, they slow down significantly with thinker metals, impacting overall production efficiency.

Cost Considerations

Laser cutters — especially fiber lasers — typically come with higher upfront costs. They also require more electricity, and the maintenance is more expensive. Plasma cutters are a more affordable option, both when it comes to the initial investment and the power costs. 

Maintenance and Safety

Plasma cutters are easier to maintain than laser cutters, which require regular calibration and are sensitive to dust and debris. However, they produce hot sparks, UV radiation, and fumes, requiring PPE and ventilation. With their enclosed systems, laser cutters are safer, but their high-intensity beams require trained operators to follow strict safety protocols.

Which Cutting Machinery is Best?

So, with all those differences in mind, which type of cutting machinery is best? The answer depends on the particular needs of your shop and the type of products you want to create. 

Plasma cutters are generally best for structural steel shops, fieldwork, and heavy equipment fabrication applications. They’re more affordable, as well, making them better for fabricators on tight budgets. Laser cutters are ideal for applications that require extreme precision, such as electronics and fine decorative work. They can also handle a lighter gauge of sheet metal than plasma cutters.

Here’s an at-a-glance comparison of their features to help you with your decision:

• Cut quality

• • • Plasma: Good
    • Laser: Excellent

• Speed

• • • Plasma: Faster on thick material
    • Laser: Faster on thin material

• Cost

• • • Plasma: Lower upfront cost
    • Laser: Higher upfront cost

• Maintenance

• • Plasma: Easier
  • Laser: More technical

Quality Cutting Equipment from Sanson Machinery

Whether you decide to go with a laser cutter or a plasma cutter, turn to Sanson Machinery for the most reliable equipment in the industry. We’re proud to offer a wide range of makes and models, ensuring you can get the quality metalworking solutions you need. If you’re still unsure which type of cutting machine is right for you, contact us today for personalized recommendations and expert guidance.

Everyone makes mistakes — even skilled professionals can run into fabrication errors. Mistakes can cost you significant money, time, and materials. However, many of them can be avoided with a bit of extra precision, planning, and the right tools. 

In this blog post, we’ll highlight some frequent mistakes in the metal fabrication process, explore expert tips for avoiding these pitfalls, and how proper machinery and tools can reduce or eliminate many manufacturing issues.

Mistake #1: Inaccurate Measurements

You’ve probably heard the phrase, “Measure twice, cut once.” There’s a reason it’s so common — it’s true! Measurement errors can throw off entire fabrication projects, leading to misaligned parts, material waste, and failed quality checks. 

To avoid this, use precision measuring tools, and double-check all measurements before cutting or welding. Consider digitizing the measurement process with CNC machines and CAD software.

Mistake #2: Ignoring Material Properties

When working with metal, it’s important to recognize that not all types of metal behave the same. Different materials require different manufacturing processes to prevent warping, cracking, reduced strength and durability, and compromised aesthetics. 

If you’re considering working with a material you don’t have much previous experience with, take some time to understand the metal’s grain structure, hardness, and thermal behavior. Choose the right fabrication techniques and machinery to the material’s unique properties, and train your shop employees on the specifics of working with this metal.

Mistake #3: Skipping Equipment Maintenance

Equipment maintenance isn’t fun, but it’s an essential part of running a fabrication shop. Ill-maintained machinery is a recipe for imprecise work, unexpected breakdowns, and safety hazards. 

Implementing a regular maintenance schedule is worth the time and effort. It’s an investment in the efficiency of your daily operations and the quality of your output. Train your staff to recognize signs of wear or malfunction. If your machinery is nearing the end of its lifespan, invest in high-quality replacements with good manufacturer support.

Mistake #4: Poor Welding Practices

Welding is a skill that takes a lot of time to master. Unfortunately, welding mistakes are common, jeopardizing the integrity of metal structures with weak joints, excessive spatter, corrosion, or distortion. 

If you’re looking for ways to improve the quality of your shop’s welded products, ensure your welders are properly trained on using the right welding techniques and settings for each type of metal, and ensure they maintain proper cleanliness of surfaces. 

Mistake #5: Neglecting Safety Protocols

There’s a saying that’s often tossed around in industrial settings: “Safety regulations are written in blood.” While it may sometimes be inconvenient to follow safety protocols, they exist for a reason. Rushing or skipping these important steps can result in injuries, accidents, project delays, and legal liabilities. 

As the boss, it’s your job to provide proper PPE and enforce its usage, keep machinery up to code with safety guards and emergency stops, and conduct regular safety training and drills. You’ll be glad you did when you avoid disaster.

Mistake #6: Not Accounting for Tolerances

Tolerance is the allowable deviation from specified measurements. Depending on the project, the tolerance can range between a few hundredths to a few thousandths of an inch. When you assume a part has exact dimensions without factoring in tolerance, parts may not fit or function properly, causing assembly issues and performance failures. 

You should always define and follow tolerance specifications in plans and drawings to account for miniscule deviations, and train your staff to do the same. If near-exact measurements are especially critical, use high-precision machinery to minimize inconsistencies. 

How the Right Machinery Can Prevent These Mistakes

Investing in the right machinery is one of the most effective ways to prevent common metal fabrication mistakes and improve the quality of your products. Consider adding a CNC machine, press brake, shears, or other precision tools to your shop to reduce human error and switching to automated systems to ensure consistent results. 

Choosing advanced equipment isn’t just about achieving higher speeds; it’s also about accuracy, efficiency, and long-term reliability. Plus, modern equipment often comes with built-in safety features and digital controls, facilitating ease of use.

Avoid Fabrication Mistakes with Sanson Machinery

At Sanson Machinery, we specialize in providing high-quality, precision fabrication machinery designed to reduce costly mistakes and improve results. Don’t hesitate to reach out to us for expert advice on selecting the best equipment for your shop or to receive a quote on any of our machinery.