Oxy-fuel cutting is a widely used thermal method in metal processing. Plasma cutting, on the other hand, is a younger and far more modern technology that is gradually gaining dominance in the market.

But is plasma the answer to all manufacturing challenges?

Production Time

Plasma cutting is faster and significantly more precise, allowing for major time savings.
Cutting with oxy-fuel can take up to seven times longer than cutting with a plasma cutter.
Additionally, plasma cutting does not require preheating.

Accuracy

Oxy-fuel cutting leaves a considerable amount of slag on the cut edges. Removing it requires additional labor and time.

Plasma cutters offer far greater precision and produce a narrower kerf, which reduces material waste and improves overall quality.

Cutting Capabilities

A plasma cutter is extremely versatile. It is suitable for cutting carbon steel, stainless steel, and non-ferrous metals.

Plasma excels at cutting thin materials quickly and does not deform sheet metal thanks to a smaller heat-affected zone.

As material thickness increases, the cutting speed of plasma becomes closer to that of oxy-fuel—and at very large thicknesses, oxy-fuel begins to win. Oxy-fuel technology can cut materials up to 150 mm thick.

Bar chart comparing relative cutting speed of mild steel, showing that the Powermax85 plasma system cuts over 250% faster than an oxy-fuel system at 0.47-inch material thickness and remains faster at greater thicknesses.

Hypertherm data (source) clearly shows that plasma cutting is significantly faster than oxy-fuel cutting.

Oxy-Fuel Cutting Requires Certification

Acetylene in pure form is colorless and odorless. Its technical-grade version has a strong, garlic-like smell. Although not highly toxic, excessive concentration in the air can cause dangerous health effects.

Acetylene is also extremely explosive and burns with an intensely bright, high-temperature flame.

It is therefore only logical that such a hazardous substance requires special handling.
Anyone operating an oxy-fuel cutting torch must hold professional certification.

There are also strict regulations regarding the storage of gas cylinders on-site.

In Summary

Oxy-fuel cutting falls short when compared to plasma in nearly every category. Plasma systems are faster, cleaner, safer, and more economical.

Despite that, oxy-fuel remains indispensable—and even irreplaceable—for one specific application:
cutting extremely thick materials, where it remains the undisputed leader.