Laser vs plasma cutting — which is better, and when

What is the actual difference between laser and plasma cutting?

Laser cutting uses a focused beam of light that melts, burns or vaporizes metal along a narrow line, while an assist gas — oxygen or nitrogen — blows the molten material out of the kerf. Plasma cutting heats a gas to roughly 20,000°C, ionizing it, then uses an electric arc to melt through electrically conductive metal; that means plasma only works on conductive stock and cannot cut glass, wood or plastic. Both run on CNC machines from a vector file (DXF, DWG, AI). The core technical difference is kerf width: a laser kerf is roughly 0.1–0.3mm, a plasma kerf 1.5–4mm — and that single number is where the gap in precision and edge quality comes from.

How thick a metal sheet can each method actually cut?

With our fiber laser we routinely cut mild (carbon) steel up to 10mm, stainless up to 6mm, aluminium up to 5mm. Copper and brass thickness is confirmed for the alloy and surface; the full per-material breakdown is on the thickness guide. Industrial plasma cutting typically starts around 3mm and extends to 40mm and beyond. The reason is economic: cutting speed drops sharply as thickness increases, and matching plasma's range would require a far higher-power machine. Above roughly 10–15mm, plasma is almost always the better-justified choice. Unlike laser, plasma is relatively insensitive to metal reflectivity, so it also works on thick aluminium and copper — though edge quality stays at the level typical for plasma.

Which method leaves a cleaner edge?

A laser-cut edge is smooth, the heat-affected zone is narrow and scorching is minimal — on thin-to-mid thickness the part often needs no secondary finishing at all. Plasma leaves a wider heat-affected zone, an angled kerf taper (typically 1–5°) and often dross on the underside that has to be ground or filed off. If a part needs tight fit-up, mounting holes that line up, or a visibly clean edge, laser is practically the only justified choice. That gap also shows up in price: finishing a rough edge is a separate operation and adds to the final per-part cost.

How much do price and turnaround differ?

On steel up to 10mm, laser is faster and cheaper per part — especially on complex contours where speed and precision are both required. On thick plate the picture flips: plasma cuts thicknesses a laser either cannot reach at all or reaches only slowly and expensively. Four factors set the final price — material and thickness, total cut-line length, contour complexity (how many holes and sharp corners), and quantity. Setup cost weighs proportionally heavier on small runs, and that applies equally to both methods. Timing is agreed after the project review. Send the metal grade, thickness, drawing, finishing and quantity, required date and collection or delivery location.

When should you choose laser, and when plasma?

Choose plasma if the sheet is thicker than 10–15mm, the geometry is simple, and further edge finishing is not a problem — typically structural work and heavy steel parts. Concretely: a 3mm stainless sign, a perforated panel or an ornamental partition is a laser job; a 20mm structural steel bracket is a plasma job. A guillotine is not a third option here: it makes straight full-length cuts only and cannot produce contours, holes or ornament. Specify the required tolerance in the drawing; achievable tolerance and edge finishing are confirmed for the material, thickness and geometry.

• Specify the required tolerance in the drawing; achievable tolerance and edge finishing are confirmed for the material, thickness and geometry.
• Plasma — thick plate (above 10–15mm), simple contours, lower per-part cost on heavy stock
• Guillotine — straight lines only, cannot cut a contour

Which of the two does Craftarea actually do?

We cut metal on our own CNC fiber laser — production is in Tbilisi and we deliver across Georgia. We do not own plasma equipment: for plate thicker than 10–15mm we prepare the technical spec, route the job to a vetted partner workshop, and remain your single point of contact throughout. We also do not perform waterjet cutting, press-brake bending, milling or lathe work — on those we advise and connect you to the right workshop. Timing is agreed after the project review. Send the metal grade, thickness, drawing, finishing and quantity, required date and collection or delivery location.