Metal fabrication often requires precise cutting techniques to achieve desired shapes and sizes. Among the popular methods are plasma cutting and water jet cutting, each offering unique advantages and considerations. In this comparison, we explore the fundamental differences between these techniques, their applications, and the factors influencing their effectiveness in various industrial settings.

Plasma Cutting:

Plasma cutters utilize gas and electricity to swiftly cut through various materials, predominantly metals. The process involves forcing gas at high pressure through a nozzle, where it encounters an electric arc, creating plasma—a fourth state of matter. This superheated plasma swiftly melts through metal, yielding clean cuts. CNC plasma tables adapt to different material types and thicknesses by employing various gases like oxygen, nitrogen, or argon.

Advantages of Plasma Cutting:

  • Well-suited for steel, with some machines capable of cutting stainless steel and aluminum with proper setup.
  • Generates smooth cuts on a wide range of steel types.
  • Requires relatively low maintenance and fewer consumables compared to water jet cutting.

Water Jet Cutting:

Water jet cutting systems employ a combination of water and abrasive to rapidly erode materials along a cutting path. This process relies on high-pressure water mixed with abrasive materials such as garnet. The mixture is propelled through a ceramic nozzle, forming a precise cutting stream. CNC software guides the nozzle’s movement along predetermined paths at varying speeds based on material type and thickness.

Advantages of Water Jet Cutting:

  • Versatile, capable of cutting any material type.
  • Offers greater accuracy and precision, particularly suitable for intricate cuts.
  • Ideal for thicker plates and materials that plasma struggles to cut effectively.


Cost Efficiency: Water jet cutting is more cost-effective for thicker plates and materials where plasma cutting may be less effective. Conversely, plasma cutting tends to be more cost-effective for thinner steels due to faster cutting speeds.

Maintenance and Consumables: Water jet systems demand frequent maintenance and consume a significant number of consumables. Plasma systems, on the other hand, typically require less maintenance and fewer consumables beyond gases.

In summary, both plasma cutting and water jet cutting methods offer distinct advantages and considerations, catering to diverse industrial needs. Plasma cutting excels in speed and efficiency, particularly on thinner steels, while water jet cutting provides superior precision and versatility, especially on thicker materials and intricate designs. It’s important to recognize that each method has its own strengths and limitations, and the choice between them should be based on specific project requirements and priorities. Whether it’s the rapid, clean cuts of plasma or the precise, versatile nature of water jet cutting, both techniques play vital roles in modern metal fabrication processes.

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