The shocking reason why EVERY fabrication shop needs a plasma cutter table – you won’t believe how much faster and cheaper it can make your work! You are going to read The Ultimate Guide to Plasma Cutting Tables: Why Your Shop Needs One (and Which Type is Best for You).
Plasma cutting tables have come so far and can do so much more than many shops realize. If you’re a fabrication business looking to expand your capabilities, invest in the future of your company, or simply get more professional results at an affordable cost, a plasma table may be exactly what you’ve been missing.
In this comprehensive guide, we’ll explore everything you need to know about plasma cutting technology and tables. By the end, you’ll understand why a plasma table is a must-have for any serious metalworking operation. Let’s get started!
Credit: iStock
How Plasma Cutting Works
Before deciding if a plasma table is right for your needs, it’s important to understand the plasma cutting process. Plasma cutting uses a stream of heated gas to cut through metal. An electrical current is introduced to the gas, turning it into an ionized gas or “plasma.”
This superheated plasma gas reaches temperatures between 20,000-40,000 degrees Fahrenheit, allowing it to melt and blow away metal as it’s being cut. The melted metal is removed via compressed air or gas from the cut zone. This thermal cutting process works on electrically conductive materials like carbon steel, stainless steel, and aluminum.
Plasma cutters work much like their related cousin, laser cutters. However, plasma is a more affordable and flexible technology. While laser cutting delivers precision results for intricate products, plasma cutting works better for production fabrication applications, particularly those requiring higher volumes or thicker materials.
So in summary – plasma cutters work by using a superheated stream of ionized gas to literally melt away metal for a clean cut. This torch-based process is ideally suited for fabrication shops needing to cut a variety of parts quickly and efficiently at a lower overall cost compared to lasers.
What is a Plasma Cutting Table?
A plasma cutting table is what enables a plasma cutter to work with precision and repeatability. It provides a sturdy framework and automated controls to allow hands-free, computer-guided cutting.
Key features of a typical plasma table
– Rigid Work Surface: Normally comprised of heavy-duty steel slats spaced 2-4″ apart to support material during the cut. The slats absorb heat from the process.
– Cutting Bridge: This overhead beam houses the plasma torch and drives its motion. It traverses back and forth across the table cutting parts to programmed tolerances.
– CNC Controls: A computer controls all motion activity based on digital designs and programs. This enables complex, multi-pass cuts with accuracy.
– Automated Process: Once programmed, the table handles cutting automatically without direct operator involvement. This boosts efficiency and repeatability.
– Interface Ports: Tables feature easy material loading/unloading and connections to the plasma power supply and compressed air/gas lines required.
So, a plasma cutting table automates and computerizes the plasma process to facilitate precision fabrication work rapidly and hands-free. It turns a plasma torch into a fully-fledged CNC cutting machine.
Plasma Cutting Benefits Over Other Methods
For fabricators adding or expanding cutting capacity, plasma tables offer advantages over alternatives like flame cutting, welding, routing, shearing, and even laser/waterjet systems.
Here’s a quick overview of some key plasma cutting benefits:
Speed: Plasma cuts fast, often 90-120 inches per minute for steel. It blazes through jobs other methods struggle with.
Materials: Plasma handles carbon steel, stainless steel, and aluminum up to 1/2” thick. The process cuts a wide variety of metals.
Cost: Plasma tables are very affordable – often 1/3 the cost of comparable laser/waterjet systems. Operating costs are also low due to the inexpensive plasma gases used.
Simplicity: Once programmed, operating a plasma table is straightforward. Little specialized training is required compared to precision laser/waterjet processes.
Portability: Plasma torches are self-contained, making tables easy to relocate within a shop or between job sites as project needs demand.
Maintenance: With few complex or precision components, plasma tables require minimal daily maintenance to keep running optimally.
Finish Quality: While they don’t rival lasers, today’s plasma tables can deliver +/- 0.005″ cuts with good oxidation resistance on carbon steels with proper consumables. Low dross and spatter mean minimal part cleanup.
Plasma cutting tables deliver production cutting benefits that far outweigh the costs for many fabricators working with carbon steel, stainless steel, and aluminum. Their benefits are why they’ve become an essential technology for professional metalworking shops of all sizes.
Plasma Cutting Table Types – Choose the Right Fit for Your Shop
Not all plasma tables are created equal. Different machines have particular strengths best suited to certain applications. Do your research to pick the right model for your needs:
Small Table (4’x8′): Ideal for hobby and small job shops. These entry models have lower capacities but cost less. Focused on simple parts.
Mid-Size Table (5’x10′-6’x12′): The sweet spot for many general fab shops. Big enough for larger parts but also affordable. Versatile machines.
Large Table (8’x12′-10’x20′): For high-output manufacturing and prototype development. Extra size means higher part capacities, larger work envelopes.
Automated/Multi-Head: For mass production volumes. These cell-based units have integrated part handling and parallel cutting heads to maximize throughput.
Desktop/Benchtop: Compact models for limited space shops. Restricted to small parts typically 1/4″ thick or less but still deliver plasma cutting capabilities on smaller scales.
Oxy-Fuel/Plasma Combos: Great bang for the buck, including an auxiliary welding/heating torch. Useful for multiprocess applications.
Used/Refurbished: Save 30-50% by choosing an inspected, serviced pre-owned machine. Great option to get a larger table on a smaller budget.
By analyzing your typical work, space available, and production volumes, it’s easy to determine the right plasma table type and size matched to suit your specific manufacturing operation. Getting the right fit up front maximizes your return on investment.
Which Plasma Cutter Works Best with a Table?
The plasma torch and power supply paired with a table are also critical. These determine the machine’s cutting capabilities and part quality. While many torches pair with most tables, ask these questions when matching to your average work:
– Amperage Rating: Higher amps cut thicker materials faster. Most tables run 50-80A torches suitable for 1/8″ carbon steel.
– Cutting Speed: Factor how fast clean cuts are required. Finer torch parts can boost speed and cut quality on thinner gauges.
– Material Types: Specialty torches handle non-ferrous metals like aluminum better through optimized gas mixtures.
– Consumables: Consider compatible torch consumables and specialized options for expanded cutting abilities.
– Processes: Hybrid torches (such as CNC plasma/torch) add oxy-fuel cutting/heating as an extra bonus process.
Top brands like Hypertherm and Thermal Dynamics offer high-quality plasma systems perfectly dialed-in for tables that ensure reliable, long-lasting performance day after day. Matching the right torch characteristics to your usual projects is hugely important for maximizing a table’s full potential.
Putting It All Together: Complete Plasma Cutting Package Deals
Here’s a quick rundown on full package options available that eliminate the hassle of shopping each component separately:
Starter Package: Entry-level machine, 50A plasma system, torch basics, safety gear, 1 year parts warranty – lower investment cost.
General Fabrication Package: Medium table, 65A plasma, extended consumables, torch accessories, safety training, 3 year coverage – balanced value.
Production Package: Large table, 85A system, 5+ consumables, automated boom/parts loader, CAD/CAM software, premium service contract – optimized for high volumes.
Turnkey Installation: Fully assembled/installed system, operator training, networking/software setup, first year maintenance plan – plug and play ready to run.
Refurbishment Upgrade: Reconditioned machine bundled with new Hypertherm plasma, consumables kit, video tutorials – affordable performance boost for existing tables.
Bundling everything into optimized, application-specific packages removes equipment compatibility guesswork. It simplifies your purchasing process while ensuring the highest quality, productivity, and peace of mind from day one of operation.
Making the Investment in Your Shop’s Future
By now it should be abundantly clear that a modern plasma cutting table delivers massive advantages for any professional metal fabrication business. They enable new cutting capabilities, improve productivity levels, and drive overall cost savings – all while producing quality, precision parts.
Whether you’re an established shop looking to boost throughput or a start-up in need of a powerful addition, investing in a plasma table will pay dividends for years. With affordable upfront and operating costs, the return on investment is very achievable within a typical 12-24 month period.
Rather than replace outdated methods, consider incorporating plasma into your lineup alongside existing machines for a well-rounded offering. It’s the equipment that keeps manufacturing adaptable, competitive, and primed for future growth.
Is a Used Plasma Table Right for Your Business?
If your budget is tighter, don’t discount the option of a used plasma cutting table. With proper selection, inspection, and maintenance, pre-owned systems can deliver reliable results for years to come at 30-50% less than new prices.
Here are a few tips when shopping used:
– Inspect for wear on bridges, rails, gantries that could impact cutting accuracy over time.
– Look for hours of use under 5,000 as a machine in lightly used condition.
– Ensure all mechanical and control components move smoothly without noises or lag.
– Check that gas/electrical systems are in good shape with no leaks or frayed wires.
– Request service records to evaluate any previous repairs or component life left.
– Have a technician perform electrical and safety checks before purchase.
Start Maximizing Your Fabrication Potential Today
At this point, I hope I’ve convinced you that a modern plasma cutting table truly belongs in any professional metal shop. Their capabilities have evolved tremendously to deliver production-level results quickly, cleanly and cost-effectively.