Plasma systems are higher priced than some other cutting tools. But there is a difference between price and cost. Plasma systems' fast cutting speeds and superior cut quality deliver productivity gains, saving operators time and money. Faster cutting speeds - without any preheating of the work piece - enable operators to complete jobs quickly. Better cut quality, with less dross and better edge quality, means fewer labor-intensive finishing operations are required. And, unlike oxyfuel cutting, because most plasma systems run off of compressed air, costly cylinder rentals and delivery charges are eliminated.

Twenty years ago, this statement may have been true, as some early handheld plasma systems did not meet operators' expectations for performance on thicker material. And, plasma does offer some distinct advantages on thin materials - like a smaller heat affected zone and less warping - over oxyfuel cutting. But as plasma technology has advanced, the belief that plasma is only for use on thin materials has become outdated. Advances in torch, consumable and power supply design have allowed plasma engineers to deliver systems that provide more cutting power and thicker cutting capacity - as much as 1.75" (44 mm) or more - even as system sizes have shrunk and duty cycles climbed.

Many plasma owners purchase their first plasma system for cutting stainless steel, alumina or other non-ferrous metals. Some people continue to believe that plasma can only be used on these materials. In truth, plasma is effective at cutting any electrically conductive metal and is actually one of the world's most popular methods for cutting mild steel. Of course, plasma's ability to cut stainless steel and aluminium is one of its primary advantages over oxyfuel cutting, which is not effective on these materials. Plasma is also more effective at cutting painted, dirty or even rusted steel, which makes it an indispensible tool for heavy equipment repair, automotive restoration, farm equipment maintenance, and many other tasks.