Plasma Cutting and Laser Cutting: What’s the Difference?

Plasma cutting and laser cutting are both widely used in industrial and fabrication settings because of their ability to cut accurately through various materials. So what’s the difference? Here’s a more detailed comparison of the two methods:

Principle of Operation:

Plasma Cutting: Plasma cutting involves passing a high-velocity jet of ionized gas (plasma) through a constricted opening. This plasma jet is directed at the material to be cut, melting it and blowing away the molten metal to create a clean cut.

Laser Cutting: Laser cutting uses a high-powered laser beam to melt, burn, or vaporize material along a predefined path. The intense energy of the laser beam heats the material rapidly, causing it to melt or evaporate, and a stream of gas blows away the molten or vaporized material to create the cut.

Materials and Thicknesses:

Plasma Cutting: Plasma cutting is particularly well-suited for cutting thicker materials, typically metals such as steel and aluminum, ranging from a few fractions of an inch to several inches in thickness.

Laser Cutting: Laser cutting is versatile and can cut through various materials, including metals (steel, stainless steel, aluminum), plastics, wood, ceramics, and composites. It is especially effective for thinner materials, but it can also handle thicker materials depending on the laser power. However, lasers may be less effective on highly reflective materials like copper.

Accuracy and Precision:

Plasma Cutting: Plasma cutting is known for its speed and efficiency, but it has a wider kerf (the width of the cut) and a rougher edge than laser cutting. The high heat can cause warping on thin materials, and it may not offer the same level of precision as laser cutting, especially when cutting intricate or detailed designs.

Laser Cutting: Laser cutting provides exceptional precision with a narrow kerf, smooth edges, and minimal heat distortion. It can also achieve very fine cuts with smooth edges, making it suitable for intricate patterns, small features, and high-tolerance parts.

Heat Affected Zone (HAZ):

Plasma Cutting: Plasma cutting generates significant heat during the cutting process, leading to a larger heat-affected zone (HAZ) than laser cutting. This can result in more thermal distortion, especially in thinner materials.

Laser Cutting: Laser cutting produces a narrower HAZ than plasma cutting, minimizing thermal distortion and reducing the need for secondary processing or post-cutting cleanup.

Operating Costs:

Plasma Cutting: Plasma cutting systems are generally more affordable to purchase and maintain than laser cutting systems. Consumable costs, such as plasma torch tips and electrodes, are relatively low.

Laser Cutting: Due to the complexity of optics and gas systems, laser cutting systems have higher initial investment costs and may require more maintenance. However, they offer lower operating costs in the long run due to higher cutting speeds and lower consumable usage for specific materials.


So which one is better? Really the best choice between plasma and laser cutting depends on your specific project requirements.

You Might Choose Plasma Cutting for:

  • Fast, cost-effective cutting of thick conductive metals.
  • Simple cuts where a smooth finish is optional.

You Might Choose Laser Cutting for:

  • Precise cuts with minimal heat distortion.
  • Cutting intricate designs and shapes.
  • Versatility for a broader range of materials beyond metals.

At Goodhart Sons, Inc., we firmly believe in having the right tool for the job. Our team has decades of experience in fabricating complex weldments and parts using both plasma and laser cut pieces, and has the expertise to meet your project’s unique needs. Request a quote for your organization today or contact us online for more information.


Heather Long

Director of Business Development