If you have never owned a plasma cutter before then the whole process of buying a machine and using it for the first time can be a lot to take in. In this guide we will help point out some basic features to look for when purchasing a plasma cutter to insure you get a machine that you will be happy with in the long run. Secondly, we will walk you through the entire process of pulling the machine out of the box to making your first cut safely. If you’re already familiar with the basics of plasma cutting and need a buyer’s guide then check out our Plasma Cutter Reviews page.

Disclaimer: This guide is for educational purposes only. Please read all documentation and safety requirements for your specific machine before using it.

In the plasma cutter market, paying a higher price for a name brand machine translates to a machine with great performance, durability, manufacture support and cut quality. To be honest, there are some cheap machines out there that can make some very impressive cuts on thick 1/2” mild steel, but the question is how long will they make those cuts until one of the cheaply made components on the machine breaks? If you stick to name brands like Miller, Hypertherm and Lincoln you can buy with confidence knowing your machine will last you many years even under heavy usage.

That being said not everyone is looking for a professional grade machine and there are a lot of inexpensive alternatives that can be a great value. If you’re a weekend warrior who is simply looking to add a basic plasma cutter to your shop on a budget, then there are a lot of great options out there for less than $1000. Take a look at our guides below to see what machines we recommend.

• The Best Plasma Cutters Under $300, $500, $700, $1000, $1500 and $2000
• The Best Plasma Cutters Under $500

We find that Hypertherm and Miller provide the most bang for your buck. Both companies offer plasma cutters that are quality built, have large part availability, and great performance. These are machines that will cost you a bit of money up front, but will pay for themselves in reliability over time. Here are the three machines that we recommend over all else.

Some plasma cutters are made with built in air compressors to supply the machine with air while you cut. These types of machines are made for users who want a mobile machine that can cut in places that don’t have an air compressor available. That being said these machines are normally underpowered and are a lot more expensive. We recommend only picking up one of these machines if you really need that mobility feature. Otherwise steer clear of these and use your extra money to buy a compressor for your shop if you don’t have one.

• The Best Plasma Cutters With Built In Compressors

While cutting metal the majority of all of the sparks and molten metal will be shooting toward to the floor. However, when you first start a cut there is always a chance that metal will spray upwards until the plasma has completely pierced through the piece of metal you are cutting. People generally call this “blow back.” This is usually the case with thicker metal and only happens for a fraction of a second. However, the sparks are still substantial enough to cause burns through your cloths and on your head. This is why safety equipment is very important.

Steel toe boots are also a strong recommendation if you will be cutting heavy sections of metal. You always want to be clear of where the metal will fall after you make your cut to prevent injury and burns. However, as with most tools sometimes other factors distract us from remembering this and accidents do happen. My steel toe boots have saved me a few times from situations like this.

Now I know some of you reading this are blue collar guys who will laugh at half of the things on this list and think “I don’t need all that. Just give me a helmet and some gloves.” Well, that was me when I first started. And guess what after having dripping hot steel fall down my untied boots burning my foot, my damn hair almost catching on fire, holes through 90% of my work shirts from sparks, and metal pieces dropping and smashing my toes I learned that using this safety equipment is worth every penny. So do as you wish, but in my opinion the safety equipment is worth every penny. And remember NEVER cut without eye protection.

• The Best Welding and Plasma Cutter Helmet

1. Turn on your air compressor and start building air pressure
2. Open windows in your shop to help ventilate air
3. Clean you surrounding area and make sure there are no fire hazards
4. Get you metal positioned in a vice, on sawhorses, or clamped to a table.
5. Check to make sure the cut metal will not hit you or your plasma cord when it drops
6. Clean the selected cut area with a wire wheel or grinder to bare metal
7. Draw your cut line with metal chalk or any other marking device
8. Hook the ground clamp of the plasma cutter to the piece of metal that will stay stationary once the cut is made
9. Put on your safety equipment
10. Plug in your plasma cutter and plug in your air hose
11. Double check that your machine is receiving both power and air
12. Line up your body to the piece of metal so that you are furthest from the sparks, have a clear view of your cut and are safe from the piece of metal falling once its cut.
13. Double check that you can move the plasma torch through the full range of motion of your cut without having to reposition mid cut.
14. Flip down your plasma hood
15. Position your plasma torch slightly off the piece of metal to prevent blowback if possible (this will not be possible if you are starting a cut in the middle of a piece of metal)
16. Press the switch or button on your torch and make the cut using a slow smooth range of motion
17. Continue the cut until you hear the metal hit the floor
18. Let the metal cool before you pick it up off the ground (small pieces of metal tend to be a lot hotter)

I hope this guide is helpful for all of you out there. I know that getting a new tool is exciting and I wanted to make a guide to get people up and running as fast as possible. I personally think a quality plasma cutter is a crucial tool for anyone who is into metal fabrication. They save you a ton of time and really open up your options when it comes to building just about anything metal related. I hope you enjoyed this guide and thank you for reading!