Laser Cutting vs Plasma Cutting (Complete Guide)

Both laser cutting and plasma cutting services use CNC technology to create intricate and specific prototypes via a range of materials, including our mild steel cutting. However, they are best suited for different purposes to get the most accurate results. In this article, we look at key differences between the profile cutting methods, from cutting speeds to ideal thicknesses so you understand the best process for your project.

What is laser cutting and how does it work?

Laser cutting is a high precision thermal cutting process that uses a focused laser beam to melt, burn or vaporise material. The laser is guided by CNC software, allowing complex shapes to be cut repeatedly with excellent accuracy.

The process works by concentrating intense light energy onto a small focal point. This heats the material rapidly while assist gases such as oxygen or nitrogen remove molten material from the cut edge. The result is a clean, narrow kerf and minimal heat affected zone.

Laser cutting is commonly used where tight tolerances, clean edges and fine detail are required.

Types of laser cutting

Different laser technologies are used depending on material type and thickness.

• Fibre laser cutting: Fibre lasers are the modern industry standard for metal cutting. They generate and amplify the laser beam through optical fibre cables doped with rare earth elements such as ytterbium, producing a highly efficient and precise cutting source.

• CO₂ laser cutting: CO₂ lasers operate using a gas mixture that typically includes carbon dioxide, nitrogen, and helium as the lasing medium. This technology has traditionally been used for cutting non metals and thinner materials.

Advantages of laser cutting

Laser cutting offers several clear benefits for precision applications.

• Precision & Accuracy: Laser beams are extremely focused, allowing for very precise cuts, tight tolerances of approximately 0.1 mm or better, and complex geometries that are difficult to achieve with plasma cutting.

• Superior Edge Quality: The process produces smooth, clean edges with little to no burrs or dross, which often reduces or completely removes the need for secondary finishing.

• Versatility:Laser cutting can be used on a wide range of materials including metals, plastics, wood, and ceramics, while plasma cutting is limited to electrically conductive materials.

• Faster for Intricate Designs: For thin materials with detailed or complex patterns, laser cutting is often faster and more efficient than alternative cutting methods.

Disadvantages of laser cutting

Despite its precision, laser cutting is not always the best choice.

• Harder Cutting Thicker Materials: Laser cutting becomes increasingly difficult on thicker materials, typically above 19 to 25 mm, where plasma cutting performs significantly better and can handle much greater thicknesses.

• Higher Cost For Thicker Materials: As material thickness increases, laser cutting becomes less efficient and more expensive compared to plasma cutting.

• Unable to Cut Reflective Materials: Highly reflective materials such as copper and brass can interfere with laser performance, making them difficult to cut, whereas plasma cutting handles these materials more effectively.

Laser cutting speeds: how fast is laser cutting?

Laser cutting speeds depend on material type and thickness.

For thin to medium mild steel, laser cutting is extremely fast, often outperforming plasma in accuracy driven applications. As thickness increases, speeds reduce and cutting becomes less economical compared to plasma.

Laser cutting is best suited to thin and medium gauge materials where speed and precision matter equally.

Laser cutting materials: what can be laser cut?

Laser cutting works well across a range of metals.

• Mild steel

• Stainless steel

• Aluminium

• Certain alloys

Material reflectivity and thickness influence feasibility, but laser cutting remains a versatile option for precision metal profiling.

Laser cutting thicknesses: what is the maximum thickness?

Laser cutting is most efficient up to moderate thicknesses.

• Thin sheet to medium plate performs best (from 1mm to 8mm).

• Accuracy reduces as thickness increases.

• Thick plate becomes slower and more expensive.

Laser cutting cost: is laser cutting expensive?

Laser cutting costs reflect its precision and technology.

• Higher machine and operational costs.

• Best value on thin to medium materials.

• Reduced secondary finishing can offset costs.

What is plasma cutting and how does it work?

Plasma cutting uses a high velocity jet of ionised gas to cut electrically conductive materials. An electric arc heats the gas to plasma state, which then melts the metal while blowing molten material away.

CNC plasma cutting is widely used for heavy duty steel profiling where thickness and speed are more important than ultra fine detail.

Types of plasma cutting

Plasma cutting technology varies based on precision requirements.

• Conventional plasma cutting: Uses compressed air as both the plasma gas and the shielding medium. It is well suited to general purpose cutting of steel, stainless steel and aluminum.

• High definition plasma cutting: Delivers enhanced edge quality, improved dimensional accuracy, and reduced angularity, often producing results close to laser cut standards.

Advantages of plasma cutting

Plasma cutting is highly effective for structural and heavy steel work.

• Thickness Capability: Allows plasma systems to cut much thicker materials, including metals over 16 mm, more efficiently and quickly than laser cutting.

• Quicker Speeds on Thicker Materials: Significantly faster than lasers, improving productivity when working with heavy plate.

• Material Versatility (Conductive): Enables plasma cutting to process any electrically conductive metal, including reflective materials such as copper that are difficult for lasers to handle.

• Simplicity & Maintenance: Simplicity and maintenance requirements are lower, as plasma machines are generally more robust and easier to maintain in house than complex laser systems.

Disadvantages of plasma cutting

Plasma cutting does have limitations.

• Wider Kerf: Wider kerf widths result in rougher edges and increased bevel, often requiring additional post processing such as grinding, particularly on thinner materials.

• Expensive for Thinner Materials: Higher when cutting thin materials, where laser cutting is typically more economical.

• Heat-Affected Zone (HAZ): The HAZ is larger, which can change material properties near the cut edge and may be undesirable for precision applications.

Plasma cutting speeds: How fast is plasma cutting?

Plasma cutting excels in speed when cutting thicker materials.

• Rapid cutting on medium to thick materials

• Consistent speed across varying thicknesses

• Ideal for large batch profiling

High definition plasma systems bridge the gap between speed and accuracy for industrial steel cutting.

Plasma cutting materials: What can plasma cut?

Plasma cutting is suitable for electrically conductive metals.

• Mild steel

• Stainless steel

• Aluminium

Plasma cutting thicknesses: How thick can plasma cut?

Plasma cutting handles significantly thicker materials than laser cutting.

• Effective on very thick steel plate (Up to 60mm)

• Maintains speed and reliability

• Ideal for heavy engineering components

Plasma cutting cost: Is plasma cutting cheaper?

Plasma cutting is generally more cost effective for thicker materials.

• Lower cost per cut on heavy plate

• Faster processing reduces labour time

• Efficient for large profiles

For projects where thickness outweighs fine detail, plasma offers excellent value.

Conclusion: What type of cutting is best for you?

When deciding between laser cutting vs plasma cutting, the right choice depends on your material, thickness requirements and the level of accuracy your project demands. Laser cutting is best suited to thin and medium gauge materials where precision, clean edges and tight tolerances are essential, particularly for components that require minimal finishing or exact repeatability. Plasma cutting, on the other hand, is the more practical and cost effective option for thicker steel plate, offering faster cutting speeds and reliable performance for heavy duty and large scale applications.

At RMP Products, we provide high definition plasma cutting services, which allows us to recommend the most efficient and accurate cutting method for each individual project. If you are looking for accurate profile cutting, contact us today for more details.