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![Plasma Cutting](/images/uploads/e3e61a5c-6ce4-4c0d-9369-de62635c2488/plasma-cutting-service-cnc-plasma-torch-steel-plate-1920x1080.jpg)

Category

# Plasma Cutting

Plasma cutting for steel: thickness, tolerances and what a quote needs

Plasma cutting uses a jet of electrically ionised gas to melt and blow away a narrow line of metal — faster than sawing, and unlike oxyfuel flame cutting, it works on any electrically conductive metal, not just carbon steel. This page covers what actually decides the outcome: the tolerance a shop can commit to, how thick the process reaches per material, the kerf it removes, and the six things a provider needs from you before it can quote a firm price instead of a range. Where suppliers publish conflicting or no figures, this page says so rather than filling the gap.

## Tolerances

| Process | Form |  | Tolerance |  |  |
|---|---|---|---|---|---|
| Repeatability | — | — | ±0.381 mm | Supplier-published | Source: Benedict-Miller — published cut repeatability of ±0.015 in (0.381 mm) on plasma-cut parts, with square edges typically held within about half a degree; a machine repeatability figure, not a guaranteed finished-part tolerance |
| Standard-definition plasma | — | Up to 10 mm | ±0.5 mm down to ±0.38 mm | Supplier-published | Source: Hypertherm — published tolerance ±0.38-0.5 mm (±0.015-0.020 in) for standard-definition plasma on steel under 10 mm thick; also reports edge angularity of about 1° on 12-38 mm steel and less than 1° on 50 mm steel |
| High-definition plasma (X-Definition) | — | — | ±0.5 mm | Supplier-published | Source: Hypertherm — X-Definition (high-definition) plasma, published as capable of maintaining EN ISO 9013 Class 1 and Class 2 tolerances, with about 0.020 in (0.5 mm) generally acceptable; describes a specific high-end system, not standard-shop plasma |

Read against EN ISO 9013, class 2. Indicative figures published by equipment makers and suppliers, not a quotation. Confirm what is achievable for your grade, thickness and quantity with the provider.

## Thickness limits

| Material | Process | Thickness |  |  |
|---|---|---|---|---|
| Carbon steel | Published shop range | 0.8 – 25.4 mm (0.032 in - 1 in) | Supplier-published | Source: Benedict-Miller plasma cutting service page — mild steel range .032 in to 7/8-1 in |
| Steel plate | Published shop range | 4.75 – 38.1 mm (0.187 in - 1.50 in) | Supplier-published | Source: Haynes International plasma cutting capability page — 0.187 in to 1.50 in; material over 1.50 in is sent to waterjet cutting instead |
| Carbon steel | Recommended for best cut quality | 15 – 50 mm | Supplier-published | Source: Fractory — recommended plasma cutting thickness for good quality on carbon steel is roughly 15 to 50 mm |
| Stainless steel | Recommended for best cut quality | 15 – 50 mm | Supplier-published | Source: Fractory — states the same recommended 15-50 mm range applies to stainless steel |
| Aluminium | Recommended for best cut quality | up to 40 mm | Supplier-published | Source: Fractory — plasma cutting on aluminium should not go past about 40 mm for good quality |
| Carbon steel | Maximum capability, quality drops before this limit | up to 150 mm | Supplier-published | Source: Fractory — states plasma is capable of cutting up to 150 mm overall, though cut quality drops well before that limit |

Indicative figures published by equipment makers and suppliers, not a quotation. Confirm what is achievable for your grade, thickness and quantity with the provider.

## Kerf width

1.5–5 mm per cut

Supplier-published

Source: Hypertherm — published plasma kerf ranging from about 1.5 mm (0.05 in) on thin metal up to roughly 5 mm on thick material at higher amperage

## What drives the price

- Material thickness
- Steel grade
- Cut complexity — straight or contour
- Total volume
- Tolerance requirement
- Finishing — deburring or secondary machining

## What a quote needs

- Grade or material number
- Plate thickness and dimensions
- Contour or a drawing file
- Required tolerance
- Whether you need an inspection certificate
- Delivery address and required date

## Traceability and EN 10204 certificates

- 2.1
- 2.2
- 3.1
- 3.2

Standard for steel purchases: 3.1

The certificate belongs to the material, not to the cut. Plasma cutting does not create an EN 10204 certificate — the real question is whether traceability survives the cut, and how pieces are marked so it does.

Standard-defined

Source: EN 10204 defines inspection-document types.

## Services

What tolerance can plasma cutting achieve?

It depends on the equipment and the segment quoted. Benedict-Miller publishes ±0.015 in (0.381 mm) cut repeatability with square edges typically held within about half a degree. Hypertherm, a plasma equipment maker, publishes ±0.38-0.5 mm for standard-definition plasma on steel under 10 mm thick, with edge angularity of about 1° on 12-38 mm steel and less than 1° on 50 mm steel. Their high-definition X-Definition process is published as capable of holding EN ISO 9013 Class 1 and Class 2 tolerances, with about 0.5 mm generally acceptable — but that describes a specific high-end system, not standard-shop plasma. Confirm the achievable tolerance for your grade, thickness and quantity with the provider.

How thick a steel plate can be plasma cut?

Published ranges vary widely by shop and equipment. Benedict-Miller's mild-steel range runs 0.032 in to 1 in (0.8 mm to 25.4 mm). Haynes International's plasma table covers 0.187 in to 1.50 in (4.75 mm to 38.1 mm) of plate, sending anything thicker to waterjet cutting instead. Fractory recommends roughly 15 to 50 mm for the best cut quality on carbon and stainless steel, up to about 40 mm on aluminium, and states plasma is capable of up to 150 mm overall — though quality drops well before that limit. There is no single "plasma cuts up to X mm" answer; ask the provider what their machine and their quality standard actually deliver.

How wide is the plasma kerf?

Hypertherm publishes a plasma kerf ranging from about 1.5 mm on thin metal up to roughly 5 mm on thick material at higher amperage — narrower than flame cutting's kerf, wider than laser's. The material lost to the cut adds up across many cuts, so include it when you calculate how much stock a job consumes.

How big is the heat-affected zone?

Hypertherm, a plasma equipment manufacturer, publishes a typical heat-affected zone under 0.25 mm for modern plasma systems — narrower than oxyfuel flame cutting, which trade sources describe only qualitatively as wider. That figure describes well-tuned, modern equipment; no independent standard sets a heat-affected zone width, and it is not a guarantee every shop's machine will match it. Ask the provider what their own equipment achieves if HAZ matters for your application.

What materials can plasma cutting handle?

Plasma cutting works on any electrically conductive metal — carbon steel, stainless steel, aluminium and other non-ferrous metals — because it melts the material with an ionised gas jet rather than by oxidising it. That is the key difference from oxyfuel flame cutting, which is limited to plain carbon steel and wrought iron. Cut quality and achievable tolerance still vary by material and thickness, so confirm both with the provider.

Plasma or laser cutting — which should I use?

Both are thermal processes, but they suit different jobs. Laser holds tighter tolerances and a narrower kerf on thinner material, with a smaller heat-affected zone. Plasma reaches thicker sections at lower equipment cost and, according to Hypertherm, out-cuts a 15 kW fibre laser above about 16 mm mild steel and a 20 kW laser above about 20 mm — the exact crossover depends on the laser's power. For thin sheet with tight tolerances, laser is usually the better choice; for mid-to-heavy plate, plasma is often the more economical one.

Plasma or flame (oxyfuel) cutting — which should I use?

Plasma and oxyfuel flame cutting overlap on mild and carbon steel, but not on much else — flame cutting cannot cut stainless steel or aluminium, plasma cuts both. On carbon steel, plasma generally gives a narrower kerf, a smaller heat-affected zone and a faster cut in the low-to-mid thickness range; flame cutting stays capable on much heavier plate, where its slower speed matters less. If your material is anything other than plain carbon steel, plasma is the only one of the two that applies.

What information do you need for a quote?

Send the grade or material, the plate thickness and dimensions, the contour or a drawing file, and the tolerance you actually need. Say whether you require an inspection certificate, and give the delivery address and the date you need it. Those six things turn an enquiry into a firm price instead of a range.

Do I get an EN 10204 3.1 certificate?

EN 10204 defines inspection document types 2.1, 2.2, 3.1 and 3.2, and 3.1 is the usual buyer default in steel procurement. But plasma cutting does not create a certificate — the certificate belongs to the material. What matters is whether traceability survives the cut, and how each cut piece is marked so it stays linked to its heat. Ask the provider that directly.

Is there a minimum order quantity?

There is no industry-wide minimum order quantity for plasma cutting; it varies by provider. Benedict-Miller advertises no minimum at all, but that is one supplier's offer, not a norm you should plan around. Ask as part of your enquiry.

What is the lead time?

No general lead time can be stated honestly — it varies by provider, and with the section, quantity and the shop's current load. Ask for a committed date with your quote.

What does plasma cutting cost?

Plasma cutting is not priced from a single rate, so any figure quoted here would mislead. What drives it is material thickness, steel grade, whether the cut is straight or a contour, total volume, the tolerance you require, and any finishing such as deburring or secondary machining. Send the six items in the quote checklist and you will get a firm price instead of a range.

## Related services

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### Contract sawing

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### Flame Cutting

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### Slitting

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### Waterjet Cutting

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### Shearing

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### Cutting to length

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