Cut to the Chase: Laser vs. Plasma vs. Waterjet Cutting Explained
- SEO Growth Access Team
- 2 days ago
- 5 min read
If you work in construction or manufacturing, you value high tech methods and equipment for their speed, efficiency, and conservation. But you may feel ambiguous about which of these is best for your steel fabrication needs.
Not all high tech solutions are created equal. Understanding the strengths of each cutting method and what kinds of projects they are suited for will help you choose the right one for a particular job.
Madden Fabrication explains the unique power of laser, plasma, and waterjet cutting, and then provides a guide for how to decide which one to use.
Table of Contents
Why the Cutting Method You Choose Actually Matters
The cutting method impacts different facets of a project, such as:
Edge quality
Amount of cleanup required
Speed of cutting
Overall cost
In addition, the size, thickness, and desired shape of the metal place constraints on the steel fabricator’s cutting method selection.
The professionals at Madden Fabrication are experts in the industry who can decide which is the best method for your project.
Laser Cutting: Precision Powered by Light
If speed and extreme precision are essential to your project and you’re cutting metal between thin and medium thickness, laser cutting is the way to go. Laser cutters use focused light beams and compressed gas to cut into the surface of the metal. The light beam concentrates cutting energy over a small area, predetermined and guided by a computer numerical control (CNC) system, which also allows the job to be scaled up without a drop in quality.
As the laser beam moves over the surface, it heats, melts, or vaporizes the metal, and the compressed gas forces the residue away from the cut. This is a very efficient process that lowers the probability of error (even in narrow, intricate designs) and of deformation of the material.
Laser cutting’s accuracy and precision definitely make this cutting method an attractive choice, but it does have some disadvantages:
Higher upfront cost for equipment
Inefficiency when used to cut reflective metals, which deflect energy from the laser beam
Greater energy consumption
Hazardous fumes requiring adequate ventilation
Is Waterjet or Laser More Accurate?
Lasers are typically more accurate, with a tolerance of 0.1 mm, whereas the tolerance for waterjetting is five times that amount. However, if you are cutting a thicker material, waterjetting will be more effective (and accurate) because lasers are unable to cut metal thicker than 25 mm.
Plasma Cutting: Raw Power Meets Rapid Results
Like laser cutting, plasma cutting also uses compressed gas, but instead of a light beam, super-heated gas (such as oxygen, nitrogen, argon, or hydrogen) forced out through a nozzle makes the desired cuts. If speed is critical for your steel cutting job, plasma cutting might be just what you need.
Possible downsides to plasma cutting include:
It can only be used to cut conductive materials.
Absorbed heat can cause deformation of the metal.
It usually doesn’t leave finished edges.
With a tolerance of 1.6 mm, it is not as precise as other cutting methods. This means more material must be used to yield parts of the same size.
What Metals Cannot Be Cut With a Plasma Cutter?
The following are some of the non-conductive materials that aren’t compatible with plasma cutting:
Wood
Rubber
Plastic
Foam
Composites
Concrete
Stone
Glass
Attempting to plasma cut these materials can result in fires, noxious fumes, and cracking of the material being cut.
Waterjet Cutting: The Cool-Running Cutting Powerhouse
If your material is heat-sensitive, waterjet cutting is probably your best bet. An extremely high-pressure jet of water, combined with an abrasive material like garnet and aluminum oxide, cuts through 200-mm-thick metal easily and accurately. One of the most notable features of this method is that it provides a cold cut, which doesn’t cause thermal deformation.
Waterjet cutting is environmentally friendly, as both water and abrasives can be reused. However, the following drawbacks should be kept in mind:
More time consuming due to the need to slow down to maintain accuracy
More costly than laser and plasma cutting due to expensive abrasive materials
Potentially damaging to machine parts
Is There Anything a Waterjet Can’t Cut?
Waterjet cutting is not recommended for projects with:
Tempered glass: Shatters under pressure
Diamonds: Too hard to cut
Reactive materials: May cause a dangerous reaction with water
Some kinds of wood: May become stained or warped
Cutting Through the Confusion: 5 Important Things To Consider Before You Cut
#1: Material Type and Thickness
This is usually the main determining factor because it narrows down your cutting method options:
What material are you cutting? Thick steel is a conductive metal that plasma can easily cut. Lasers can cut thin steel into precise parts. Aluminum could potentially do well under any method. For nonmetals, waterjet or laser cutting may be used.
How thick is the material? Laser cutting is better for thin metals, whereas plasma can cut 10–150-mm material, and waterjets can cut 200+-mm material.
Is the material heat-sensitive or reflective? These qualities can alter laser performance, either damaging the material or making the cut ineffectual.
#2: Cost, Speed, Volume
How much are you willing to spend? Expensive abrasives make waterjets 2–4 times more expensive to operate than laser and plasma cutting. This price may be worth it if you need cold cuts or are using thicker metal. Laser cutting requires high upfront costs.
How soon do you need the product ready? Plasma and laser are the fastest choices, whereas you’ll have to take your time with waterjetting.
How much product are you making? Projects using any cutting method may be scaled up, but keep in mind waterjetting’s higher operating cost and the amount of waste associated with plasma cutting.
#3: Precision, Edge Quality, Kerf Width
What level of accuracy is required for your project? Laser cutting affords the greatest accuracy, and plasma the least.
What is the desired edge quality? Laser and waterjet cutting can both yield finished edge smoothness. Plasma cutting leaves rough edges.
How much material will be lost to the cut? The width of the blade, beam, or gas stream that makes the cut is called the kerf. This width must be subtracted from the total amount of material to determine how much is available for viable parts. Lasers have a narrow kerf and plasma a wide kerf. Waterjets leave a taper between the top and bottom of the cut due to the energy lost as the water travels through the metal piece.
#4: Heat-Affected Zone (HAZ)
Laser and plasma cutting heat up the metal in the zone around the beam or gas stream, creating a “heat-affected zone.” This heat can distort the shape of the metal and change its original properties, such as its:
Hardness: Resistance to scratches and surface damage
Weldability: Ability to withstand welding without being damaged
Ductility: Ability to stretch or bend without breaking
Toughness: Ability to withstand impact without breaking
#5: Environmental and Safety Impacts
Laser and plasma cutting both emit fumes, dust, or potentially hazardous byproducts. First consider whether the material you wish to cut will release toxic gases when heated. Then determine if your worksite has adequate ventilation to prevent harm to you or your employees. If not, waterjetting is completely safe in terms of toxicity.
However You Cut It, Madden Fabrication Delivers Quality Results Every Time
Whether you’re planning the construction of a hospital, event center, or agricultural building, you know the integrity of your structure depends on having the best-made components. At Madden Fabrication, we are committed to providing the safest, most true-to-form steel parts to make up the whole construction you have in mind.
We are well versed in different methods of steel cutting and use the most appropriate ones to establish the strength and longevity of our products, whether it be:
Beams
Railings
Metal gates
Metal awnings
And more
Contact Madden Fabrication today to learn more about our role in making your building project a reality.
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