Right Machine, Right Process | Make Informed Thermal Cutting Decisions

Choosing the right thermal cutting process is crucial for maximizing efficiency, quality, and cost-effectiveness in metal fabrication.

Choosing the right thermal cutting process is crucial for maximizing efficiency, quality, and cost-effectiveness in metal fabrication. In a recently held expert-led technical workshop by Mojo4Industry, industry professionals gained in-depth insights into the strengths and practical applications of Oxyfuel, Plasma, and Laser cutting technologies. The workshop titled “Right Machine, Right Process: Make Informed Thermal Cutting Decisions” was designed to help manufacturers, engineers, and shop-floor decision-makers select the most effective thermal cutting technologies based on material type, thickness, precision needs, and production goals.

Understanding Thermal Cutting with Messer
Duraiswamy Ravichandran, DGM – Application Engineering & Intelligent Solutions, Messer Cutting Systems India, kicked off the technical discussion with an overview of Messer’s global legacy. “Messer was founded in 1898 and operates globally, with five production plants across the world catering to different regions,” he shared.

Explaining the fundamentals of cutting technologies, Mr. Ravichandran emphasized the distinction between contact cutting and non-contact or thermal cutting processes. “Ours is a non-contact cutting process, and we use thermal energy for cutting,” he said.

He elaborated on the three main types of thermal cutting technologies:

• Oxyfuel (Flame Cutting) – suitable for cutting thick plates up to 300 mm.
• Plasma Cutting – ideal for medium-thickness materials, typically 58 mm to 120 mm, depending on the power of the plasma source.
• Laser Cutting – best for precision cutting of thinner materials, commonly up to 30 mm on production lines.

According to Ravichandran, each method has unique strengths. “For high-thickness plates, oxyfuel is the most suitable. For better precision up to 120 mm, plasma is preferred. And for thinner materials with finer tolerance, laser cutting is the ideal choice.”

He also compared the cost, quality, and productivity of the three technologies. Plasma cutting offers superior finish and higher productivity than oxyfuel and requires a relatively lower capital investment. Laser cutting involves higher initial investment but lower running costs. He emphasized the use of a bubble diagram to help visualize thickness vs. precision trade-offs and noted that with high-power lasers, laser cutting capabilities are expanding rapidly.

“For mild steel, one can choose among all three processes depending on the thickness. But for stainless steel, the choice is between plasma and laser – with plasma offering broader capability and laser offering tighter tolerances,” he concluded.

Plasma Advancements with Kjellberg
Vishal Deore, Director at Kjellberg India, focused on innovations in plasma technology and how plasma systems are evolving to meet modern fabrication needs.

Representing Kjellberg’s legacy since 1922 and its pioneering role in plasma technology since 1959, Vishal highlighted milestones such as the introduction of air plasma in the 1970s and underwater plasma in the 1980s. “German engineering is known for niche products and R&D, and at Kjellberg, our in-house company is dedicated to continuous innovation,” he said.

Kjellberg’s latest Series machines are designed with modular structures, allowing users to expand capacity by simply adding modules. “For instance, a customer can begin with a base model and later upgrade it to a 300-ampere machine,” Mr. Deore explained.

These smart factory-ready systems are Industry 4.0 compliant, offering features like remote monitoring, e-service, and even mobile app connectivity. “Even our smallest model, can be connected via a mobile app for real-time data exchange, helping with automation, inventory control, and purchase planning,” he added.

He also introduced Kjellberg’s Hot Wire Technology, a patented solution for cutting non-conductive materials like gratings and armored concrete. “This indirect plasma cutting method uses an auxiliary wire and enables high-speed cutting of interrupted workpieces,” he noted.

On the topic of plasma marking, Vishal pointed out its role in cost-effective branding on electrically conductive materials. “Today, many customers are using expensive laser systems where high-precision plasma could fulfill the same task more efficiently.”

He provided a comparative analysis of plasma versus fiber laser technologies. While fiber lasers are gaining ground due to cost and tech improvements, plasma remains highly relevant.

“Each process has its technological advantages depending on the application. Plasma handles a wider range of thicknesses – from 5 mm to 160 mm – and is ideal for greasy, rusty, or oily materials where laser may struggle,” Vishal said.

He further highlighted:

• Material Handling: Plasma systems are easier to load/unload and more forgiving in safety and operation, whereas laser systems require shuttle tables and have complex safety requirements.
• Bevel Cutting: Plasma systems support advanced beveling (Y, K, X types), unlike lasers which face physical limitations.
• Precision vs. Thickness: Laser excels at thin, intricate cuts; plasma dominates thicker material applications with consistent performance.

He concluded by encouraging participants to evaluate both short-term needs and long-term ROI before investing in CNC thermal cutting systems.