The Powermax SYNC™ series represents the next generation of Powermax 65®, 85®, and 105® systems. Designed with an integrated logic module and a groundbreaking one-piece consumable cartridge, Powermax SYNC sets a new standard for plasma cutting technology.

Product overview of the Hypertherm Powermax105 SYNC plasma system showing the power supply, SmartSYNC torch, RFID cartridges, and automatic settings with digital data display.

A Power Source From the New Series With a SmartSYNC Torch

Significantly Simplified Consumables Combined With Revolutionary Features

The simplified consumable design, together with advanced data-exchange capabilities and automatic configuration, makes Hypertherm’s new Powermax65/85/105 SYNC™ systems the smart choice for any cutting or gouging application.

What Makes the Powermax SYNC System Unique?

User-Friendly Operation

  • Consumables are color-coded by process, ensuring easy identification.
    The one-piece cartridge design eliminates mistakes related to incorrect part combinations and significantly simplifies inventory management.

  • SmartSYNC™ torches automatically set the correct amperage and operating mode, greatly reducing the risk of operator error.

  • The system monitors consumable wear and informs the operator exactly when the cartridge needs to be replaced.

Reduced Operating Costs and Maximized Productivity

  • Simplified handling reduces training time, minimizes downtime, and makes troubleshooting easier while decreasing waste.

  • The advanced cartridge design provides up to twice the life compared to standard consumables used in mechanized cutting.

  • Access to cartridge data allows users to track performance, analyze usage patterns, and optimize operations.

  • Improved torch-mounted controls allow the operator to adjust amperage and switch processes directly on the torch, without returning to the power supply panel.

Best-in-Class Reliability

  • SmartSYNC™ torches are engineered for enhanced durability in demanding industrial environments.

  • Hypertherm’s SpringStart™ technology ensures consistent starting performance and extended torch life.

Performance comparison table for Powermax65 SYNC, Powermax85 SYNC, and Powermax105 SYNC showing recommended cutting thicknesses, cutting speeds, piercing capabilities, and maximum material removal rates for gouging.

Technical Specifications of the New Powermax SYNC Series

Benefits of Using Hypertherm Cartridges

Ease of Use

  • Faster operator training and easier troubleshooting thanks to fewer consumable components.

  • Cartridges are laser-marked and color-coded by process and amperage, making identification effortless.

  • Powermax45® XP/65/85/105 systems can be upgraded to support Hypertherm cartridges using a Duramax® torch adapter.

Overview of SmartSYNC plasma torches showing 75° and 15° hand torches, a mechanized torch, interchangeable color-coded cartridges, and integrated controls with LED indicators for amperage, status, and safety functions.

Torch Types and Feature Overview

Increased Productivity

  • The optimized cartridge design maximizes productivity and performance, extending consumable life in handheld cutting and ensuring high quality in mechanized cutting.

  • When paired with SmartSYNC™ torches and the Powermax SYNC™ system, cartridges provide valuable data on usage and wear — helping improve cutting processes and identify areas for operator training.

  • Specialized cartridges, such as FlushCut™ and FineCut®, further expand the capabilities of Powermax systems.

Torch Compatibility

  • Full compatibility with all SmartSYNC torches — enabling automatic process setup and data transfer to the system.

  • An optional cartridge reader pairs with the Powermax SYNC smartphone app, allowing users to review key data such as performance metrics, number of starts and transfers, and total arc-on time.

  • Limited compatibility with Duramax and Duramax® Lock torches (used in Powermax45 XP/65/85/105 systems).
    Requires an additional torch adapter (Part No. 428951).
    Automatic process setup and data transfer are not supported in these configurations.

Informational graphic presenting SmartSYNC torch benefits for hand cutting, gouging, and mechanized applications, featuring ergonomic hand torches and a mechanized torch for CNC cutting systems.

Torch Applications

Otinus – Distributor of Hypertherm’s Latest Innovations

All the systems described above are available in our online store at Otinus.
Our plasma-source selection calculator will help you find the most suitable system for your needs.

If you have any questions about the new Hypertherm Powermax SYNC™ technology, we encourage you to contact us. We will gladly clarify all details and help you choose a system that meets your production requirements.