Cutting Expanded Steel on Plasma Table: The Basics

If you’ve worked with expanded steel on a plasma table before, you know it’s tough, versatile, and often used for things like walkways, machine guards, and grating. But when it comes to CNC plasma cutting, the big question is: can you cut it?

The short answer: yes—but it’s not as straightforward as cutting flat sheet metal.

Why Expanded Steel Is Tricky

Expanded steel on a plasma table isn’t a solid sheet. It’s made up of a diamond-shaped mesh with lots of open space. That means:

  • Your torch won’t always have consistent contact with metal.
  • Ohmic sensing (if you use it) can misread gaps.
  • Cutting paths need extra attention to avoid collisions or “lost cuts.”
  • Keep in mind you can manually set your torch height when cutting expanded steel.

Tips for Cutting Expanded Steel on a Plasma Table

  1. Secure the Material – Expanded metal can flex and bounce. Clamp it tightly so it doesn’t vibrate or shift mid-cut.
  2. Adjust Torch Height – Using a floating head or fine-tuned torch height control helps keep the cut consistent across uneven surfaces.
  3. You Don’t Want Any Lead-Ins – Avoid placing lead-ins on expanded steel. Start your cut directly on solid material to reduce misfires.
  4. Cut Speed & Amperage – A little slower travel speed paired with the correct amperage helps keep the cut clean without blowing out the edges. On a Hypertherm system, make sure to switch the Operating Mode Switch to the top position for expanded metal.
  5. Expect Some Cleanup – Because of the open pattern, dross can be a bit more stubborn. A wire wheel or grinder may be needed after cutting.

The Right Time to Use Plasma on Expanded Steel

If you’re cutting custom shapes out of expanded metal—for example, decorative panels or specific cut-outs for machinery, it can be worth the extra setup. But if you need precision cuts and perfectly smooth edges, a plasma table may not be the most efficient method compared to other fabrication techniques.

Cutting expanded steel on a CNC plasma table is definitely possible. It takes some extra planning compared to flat plate. From securing the material to dialing in your torch height and speeds, those small adjustments make the difference between frustration and a clean cut. If you’re prepared for the quirks of expanded metal, plasma can still be a reliable way to get the job done.


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