Laser cutting vs plasma cutting: In-depth comparison of steel plate processing costs and efficiency
Release time:
2025-06-16
1. Core performance comparison: accuracy, speed and applicable scenarios
Indicators Laser cutting Plasma cutting Winner
Cutting accuracy ±0.1mm (fiber laser) ±0.5~1mm Laser ✓
Cutting speed 12m/min (1mm carbon steel) 8m/min (1mm carbon steel) Laser ✓
Maximum cutting thickness 25mm (carbon steel/6kW fiber) 150mm (carbon steel/400A power supply) Plasma ✓
Heat-affected zone (HAZ) 0.2~0.5mm 1.2~2mm Laser ✓
Consumables cost Lens/gas (￥8/hour) Electrode/nozzle (￥25/hour) Laser ✓
▶ Scenario selection suggestions:
Auto parts (＜20mm stainless steel): Choose laser cutting → high precision + no burrs
Engineering machinery (50mm carbon steel): Choose plasma → strong penetration + low cost
2. Steel plate cutting cost analysis (taking 10mm carbon steel as an example)
Cost items Laser cutting Plasma cutting Difference
Equipment depreciation (yuan/hour) 180 70 +157%
Electricity consumption 32 kW/h 85 kW/h -62%
Gas consumption Oxygen ￥40/h Air ￥5/h +700%
Consumables loss ￥8/h ￥25/h -68%
Comprehensive cost ￥260/h ￥120/h +117%
Cutting cost per meter ￥4.3 ￥1.5 +186%
Key findings:
Plasma cutting has significant cost advantages in thick plate (＞15mm) scenarios, which is more than 50% lower than laser
Laser cutting wins by speed in thin plate batch processing: 1mm plate daily output can reach 3 times that of plasma
III. Practical solution for efficiency optimization
✅ Tips to improve laser cutting efficiency
Nesting optimization:
Using SigmaNEST software for nesting, material utilization rate increased from 70% to 92% (a chassis factory saves 300 tons of steel per year)
Piercing technology upgrade:
Ultra-fast pulse piercing (<0.5 seconds/hole) is 40% faster than conventional blasting piercing
Automatic nozzle change system:
Reduce downtime and increase equipment OEE (overall efficiency) to 85%
✅ Plasma cutting cost control strategy
Fine parameter adjustment:
Current reduced to 80% of the standard + speed increased by 15% → Consumables life is extended by 2 times (measured by Lincoln Electric)
Bevel cutting in one:
Complete 30° bevel in one go, eliminating the milling process (shipyard welding cost reduced by ￥60/m)
IV. New trend of technology integration: Hybrid composite cutting
Solution: Laser + plasma dual-head collaborative work
Case benefits:
After a wind power tower plant adopted the Hybrid solution:
The overall processing cost decreased by 28%
Switching plates of different thicknesses without changing the machine
V. Enterprise selection decision tree
1. Cutting material?
└─ Reflective metal (copper/aluminum) → Fiber laser (anti-reflection damage)
└─ Ordinary carbon steel → Enter question 2
2. Mainstream thickness?
└─ ＜15mm → Laser cutting (accuracy first)
└─ ＞15mm → Plasma cutting (cost first)
3. Production scale?
└─ Small batches → Outsourcing laser processing
└─ Large batches → Self-purchased equipment (laser ROI < 2 years)
Conclusion:
"There is no best cutting process, only the most suitable scenario." In 2025, laser cutting will break through the 40mm carbon steel cutting bottleneck driven by 10,000-watt power supply, and the intelligent plasma system is narrowing the gap in thin plate processing through AI parameter optimization. Metal processing companies need to establish "laser + plasma" dual-track capabilities and combine digital twin preview cutting solutions to achieve the ultimate goal of reducing comprehensive costs by 30%.
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