Best Cutting Method For Different Steel Thicknesses

Everyone who comes to us knows they need profile cutting, but many are unsure which method is best for the steel thickness they require. For example, you cannot laser cut anything much above 8 mm because it becomes too expensive. Choosing the right method for your steel thickness helps you achieve the most accurate cut at the most cost effective price. In this guide, we explain the main cutting methods and highlight the ideal thickness range for each so you can make the right choice for your project.

Why Choosing the Right Cutting Method Matters

Steel reacts differently depending on its thickness, composition and heat tolerance. Selecting the wrong cutting method can lead to:

• Rough edges that require extra finishing
• Warping caused by excessive heat
• Slower cutting speeds that increase cost
• Poor accuracy on finer details

Understanding how laser, plasma, waterjet and flame cutting behave across different thicknesses ensures your project remains accurate and cost effective.

1. Laser Cutting for Thin Steel

Laser cutting is the preferred method for thin steel.

Ideal thickness range
0.5 mm to 8 mm

Why laser works best for these thicknesses
• Produces clean and sharp edges that often need no finishing
• Cuts intricate shapes with high precision
• Fast cutting speeds for thin gauge steel
• Minimal heat distortion compared with flame or plasma cutting

2. Plasma Cutting for Medium to Thick Steel

Plasma cutting services are the best method for medium to thick steel.

Ideal thickness range
10 mm to 60 mm

Why plasma works well for thicker steel
• Faster than laser on plates above 10 mm
• More cost effective for larger or heavier sheets
• Capable of cutting coated or rusty steel
• Produces good accuracy without the higher cost of laser cutting at thicker gauges

3. Waterjet Cutting for Thin to Extra Thick Steel

Waterjet cutting is unique because it uses no heat, making it ideal for sensitive steels across a wide range of thicknesses.

Ideal thickness range
1 mm to 100 mm +

Why waterjet is ideal for complex or temperature sensitive work
• No heat affected zone, so no risk of warping
• Extremely precise for detailed shapes
• Suitable for layered materials or steels that cannot be exposed to heat
• Cuts very thick plates where laser and plasma are not suitable

4. Flame Cutting for Heavy Steel Plate

For really thick steel, flame cutting services are the preferred method.

Ideal thickness range
20 mm to 300 mm

Why flame cutting excels on heavy plate
• Highly cost effective for thick steel
• Simple equipment setup for large sheets
• Capable of cutting extremely large plate sizes
• Produces strong and straight cuts suitable for structural applications

Steel Thickness vs Cutting Method Comparison Table

Conclusion

Choosing the correct cutting method for the thickness of your steel ensures both accuracy and cost efficiency. Thin and detailed parts benefit most from laser cutting, medium to thick plates work well with plasma, very thick or temperature sensitive materials are ideal for waterjet cutting and heavy steel plate is best handled with flame cutting. By matching your material and project needs to the right approach, you can achieve consistent and professional results. At RMP Products, we are always here to support you with expert guidance and reliable cutting options to keep your project moving smoothly.