Known for its portability, user-friendly controls, and reliable plasma arc, the Hypertherm Powermax series boasts some of the most reputable plasma cutters on the market. Whether you're new to cutting or a pro, these tools cover a wide range of applications, making them a great choice for anyone.

Which Plasma Cutter is Best for you?

Two of the most popular models are the Hypertherm Powermax30 XP and the Hypertherm Powermax45 XP. This selection of machines caters to a wide range of metal fabrication needs, from cutting thinner metal projects to gouging tasks. 

Powermax30 XP

The Powermax30 XP has a host of impressive capabilities for being the less formidable of the two machines. The 30XP has a recommended cut capacity of 3/8in (10mm), a severance cut capacity of 5/8in (16mm), and an output amperage of 15-30 A. This machine supports drag cutting, fine feature cutting, and extended reach cutting or gouging. The 30XP also comes in a carrying case that includes:

• 240 V/20 A plug with adapters  or 120 V/15 A and 240 V/20 A circuits
• Hypertherm Powermax 30 XP Power supply, 15 ft. (4.5 m) Duramax LT hand torch with standard consumables, 15 ft. (4.5 m) work clamp
• Operator and safety manuals
• Consumable kit with 1 standard nozzle, 1 electrode, 1 Fine Cut nozzle, and 1 Fine Cut deflector
• Carrying strap
• Leather gloves
• Shade 5 glasses

Fully loaded with all these items, the Powermax30 XP is a good choice as an on-the-go plasma cutter.  The machine by itself weighs in at about 21lbs, making it one of the lightest plasma cutters Hypertherm has to offer. Along with its lightweight, the Powermax30 XP also offers dual voltage 120V/240V, thus enhancing its portability to plug in anywhere.

On mild steel cutting 1/8 in thickness, the Powermax30 XP outperforms traditional oxy-fuel cutting speed by over 300%. The enhanced speed of plasma cutting saves the end user both time and money. Not only is this machine fast, but as mentioned above, it allows FineCut® capabilities making it a good choice for fine-detailed and thin-metal projects. The Powermax30 XP stands out as a competitor in the realm of plasma cutters by showcasing its versatility, not only excelling at primary functions but also demonstrating the capability to gouge metal effectively. For a hobbyist or someone who plasma cuts on the go consistently or enjoys being a garage hobbyist, the Powermax30 XP is a great investment.

Powermax45 XP

As the more robust of the two machines, the Powermax45 XP is capable of everything the Powermax30 XP can do and more. This machine supports:

• Drag cutting
• Extended reach cutting and gouging
• Fine feature cutting
• Flush cutting
• Max control gouging
• Marking
• Mechanized cutting
• Precision gouging

This comprehensive list of functionalities demands a heightened level of performance from the machine.  The Powermax45 XP has a recommended cut capacity of 5/8in (16mm), a severance cut capacity of 1-1/8in (29mm), and an output amperage of 10-45 A. This machine is also lightweight at 30 lbs and comes with a lift handle on top. However, it does not offer the ability to plug into a 120V household outlet like a Powermax30 XP and is an overall larger machine dimensionally. But don’t let this detract from all the other attractive features the Powermax45 XP hosts. The Powermax45 XP is a high-performing plasma cutter with industrial capabilities and is often used as such. The unit would typically be considered overqualified to be purchased as solely a garage hobby cutter. 

This machine offers compatibility with hand torches, machine torches, robotic torches, and handheld long torches. The Powermax45 XP torches are also equipped with FastConnect™ torch to allow for quick and easy switching between torches. Hypertherm also offers a cartridge adapter that allows the torches that are compatible with the Powermax45 XP to accept the new SYNC cartridges. The SYNC cartridges are an added convenience in plasma cutting because they eliminate the need for multiple consumable pieces. Instead of having an individual swirl ring, electrode, nozzle, shield, and retaining cap, with the cartridge adapter (428951) the SYNC cartridge functions as a 5-in-1. 

Choosing your Hypertherm Plasma Cutter: Expert Guidance

In conclusion, the Hypertherm Powermax series stands as a pinnacle in the realm of plasma cutters, catering to diverse metal fabrication needs. On one hand, The Powermax30 XP, with its lightweight design and versatile capabilities, is an excellent choice for on-the-go plasma cutting tasks, boasting remarkable speed and precision. On the other hand, the Powermax45 XP offers industrial-grade performance, featuring an extensive range of functionalities and compatibility with various torch types, including the innovative SYNC cartridges for added convenience. Whether you're a hobbyist or an industrial professional, the Powermax series delivers cutting-edge technology and unparalleled performance for all your metalworking needs.
Are you ready to enhance your workshop's cutting efficiency? Decision-making can be challenging, but with the right information, it becomes simpler. Whether your interest is piqued by the compact precision of the Powermax 30 XP or the powerful versatility of the Powermax 45 XP, the ideal plasma cutter for your needs is within reach. Get in touch with us now for expert guidance tailored to your specific requirements, or explore our detailed product listings to make an informed decision. The perfect Hypertherm model for your workshop is just a step away – let's make that choice together today!

The Rise Of Plasma Cutting

Plasma cutting has been around since before the 1970s but wasn’t widely accepted until the 1980s. Since the 80’s it has just continued to excel in popularity and innovation. Plasma cutting is a powerful tool that can be used in a multitude of industrial/manufacturing settings such as:

• Fabrication
• Automotive industry
• Large structural or pipeline steel work

The speed of plasma cutting and its adaptability to multiple facets are what have helped it propel to one of the most desired shop utilities.

The Art Of Plasma Cutting

Plasma cutting sends an electrical arc through forced gas that is constricted, this raises the temperature high enough that the gas enters the 4th state of matter. The fourth state of matter is plasma. Plasma comes from inside of the nozzle down at a great force and an extreme heat to cut your metal. The gasses typically used in plasma cutting can be oxygen, nitrogen, argon or forced shop air. 

In Hypertherm Powermax 30 AIR 088096, there is a built-in air compressor within the machine. This Hypertherm plasma cutter does not require any shielding gas. With the Powermax 30 AIR it is as simple as plugging it into the wall , properly attaching your ground clamp to the material, picking up your torch and cutting! The built-in air compressor on this machine makes it highly portable and very attractive to anyone that is plasma cutting on the go. 

Some higher intensity plasma cutters that have been discussed in previous blogs (Hypertherm SYNC Plasma Cutters Role in Metal Cutting) are those of the Hypertherm SYNC series. With the latest in the industry technology, the SYNCs give you the ability to outperform other plasma cutting technologies. From the SmartSYNC® torches technology to the color coded, app-pairing consumables these machines leave all the guesswork out and help increase your project-to-project efficiency.

Effective Plasma Cutting Techniques

Tips and tricks to master these technologies almost sound too good to be true, because they are that simple to use. If you want clean, precise cuts with your plasma cutters you just have to make sure you’re checking this list. 

Tips To Clean And Precise Cuts:

1. Familiarity With Your Machine: Make sure you are familiar with your machine and its capabilities. Choose a suitable project based on your machine's abilities and available materials. Adjust materials or consumables if needed for optimal results.
2. Consumable Health: Inspecting your consumables before tasks can prevent issues. Check them for proper functioning. SYNC cartridges indicate when to change consumables, saving time. If not using SYNC, refer to this list: swirl ring, electrode, nozzle, retaining cap, shield cap.
3. Setting Adjustments: To find the right settings for your projects, practice cuts on the same material help you adjust amperage or heat. For thinner materials, a faster travel speed yields cleaner cuts.
4. Torch Techniques: Hold the torch perpendicular to the metal for a straight cut. Use a cutting guide or straight edge if needed. Maintain a proper stand-off distance to avoid damage and ensure cut quality. Torch stand-off guides can be used for assistance.

Fun Fact: Hypertherm torches have a shield technology that isolates the nozzle from the metal, so you can drag the nozzle directly on the metal, with no worry about double arcing.

Maintaining And Troubleshooting Plasma Cutters: Q&A

Like the tips and tricks section, maintaining your plasma cutter is simple and will again feel too good to be true. A lot of the same general maintenance tips that we talked about in our first series, Equipment Maintenance: The Ultimate Guide For Welders, will apply to your plasma cutter. The main takeaways being:

• Make sure your machine and consumables are clean and in good condition.
• Inspect all cables and cords for breaks or wear to confirm good electrical flow. 
• Monitor gas flow and coolant levels to help keep your machine cooled and running efficiently.

Let’s troubleshoot some scenarios:

Q: What do I do if my Hypertherm Powermax 30 AIR 088096 won’t strike an arc?

A:  Check your ground clamp or the surface your ground clamp is connected to. The ground clamp needs to be in decent condition and the surface it is connected to should be clean and free of debris. Things like paint, rust, and dirt will hinder the electrical flow to your equipment, making it difficult to strike an arc. 

An alternative problem could be that the gas flow to your torch is too high, creating a hard start. Excess gas pressure is something to be aware of because it can quickly deteriorate your consumables and damage your torch.

Q: What do I do if my Hypertherm SYNC65 083343 is burning through consumables?

A: Checking your gas flow could solve this problem. If the gas flow to your torch is too high it could cause your torch to hard start. Excess gas pressure can cause consumables, especially electrodes, to rapidly deteriorate. Also check the settings on your machine to ensure they are compatible with the consumables you are using and appropriate for the project. This is something to be gravely aware of as it can cause damage to not just your consumables, but your entire plasma system. 

Q: What do I do if my Hypertherm Powermax 45 088112 is producing excess amounts of dross?

A:  Similar to the last question, this is likely a settings issue. Double checking your amperage and gas flow, along with being mindful of the speed which you are cutting; could alone solve the problem. Another possible cause of dross is worn consumables that need to be replaced.

Revolutionizing Manufacturing: The Role Of Plasma Cutting

The role of plasma cutting in the world of manufacturing and industrial work is invaluable. Once you’ve taken the time to master your plasma cutting skills, the opportunities for increased efficiency, direct cost savings, and valuable shop time are endless. Keeping your cutting equipment in good working order, through regular maintenance, is the best way to extend machine longevity. 
In the final blog of our maintenance series we will discuss the best ways to maintain and utilize your oxy-fuel torch. Follow us on Facebook so you don’t miss out on all things new on equipment maintenance!

The Technology: SYNC Machines And Plasma Cutters

All of the SYNC machines are equipped with some of the best plasma cutting technology, such as RFID (radio frequency identification) technology that helps the machine read messages from the SmartSYNC Torches based on the attached consumable cartridges. This allows the plasma cutter to automatically adjust to the correct amperage. These consumable cartridges come specific to the job.  To further the ease of use with these cartridges, Hypertherm has made them color-coded based on application:

• Yellow - Drag Cutting
• Gray - Mechanized / Stand Off
• Green - Gouging
• Black - FlushCut®

If you already happen to own a Duramax torch, there are limited capabilities. However, it is likely that with the right torch adapter, you could still benefit from some of the features that these revolutionary consumables offer. Another thing that is appealing about these single-piece cartridges is that they save customers, on average, $57/per consumable set. You save time and money instantly through the accuracy of the end-of-life detection offered through the RFID communication technology. Hypertherm’s dedication to innovation really gives consumers the best plasma cutters with the latest technology on the market!

Plasma Cutters: Material Types & Machine Options

The three variations of SYNC machines that we are exploring all have the ability to cut mild steel (FineCut high or low speed), stainless steel, and aluminum. Which machine is right for you is ultimately going to depend on the demand of the project. As you step up the Hypertherm plasma cutting ladder first with a SYNC 65, SYNC 85, and then SYNC 105, your capabilities will expand. 

Powermax65 SYNC

The first of the series is the Hypertherm Powermax65 SYNC. The SYNC 65 has the ability to cut up to 20mm or 3 ⁄ 4'' and has a cut speed of 500 mm/min (20 ipm). This machine is the mildest performer of the 3 plasma cutters, but that doesn’t make it any less impressive. This machine would be more likely used for thicker metal sign cutting, doing some simple auto body work, or smaller projects around a fabrication shop. Personally, a SYNC 65 is likely a little more equipped than what a hobbyist would need just doing side jobs. However, it can certainly do all those side jobs and more, thus furthering its reputation in versatility. 

Powermax85 SYNC

The Powermax85 SYNC is the next in line as we step up the Hypertherm plasma cutter ladder.  This plasma cutter can cut up to 25mm or 1” and has a cut speed of 500 mm/min (20 ipm).  This machine can be considered as the happy medium. With its ability to cut a 1” thickness it proves itself to be a good choice for metal fabrication in an industrial setting or factory setting but it can do nearly all the same things as the Powermax65 SYNC, making it the shop workhorse. 

Powermax105 SYNC

The Powermax105 SYNC is the heaviest duty of the series line. This machine can cut up to 32mm or 1-1/4“ with a cutting speed of  500mm/min (20 ipm). The most common use for this machine model would be as an industrial plasma cutter, performing well in plasma cutting jobs for steel structural projects such as metal for bridges, car parks, and large pipework. This professional plasma cutter is best fitting for a much larger scale of industrial work.

Plasma Cutting Performance & Tips

When you begin to compare other plasma cutters on the market, it is a little harder to find something comparable to the SYNC series. There are plasma cutters that perform similarly to the SYNCs, but none of them come with the same perks. From the torches to the single-piece consumables, Hypertherm’s technology takes you to the next level in plasma cutting. The ease of use and application sells not only the SYNC series but all Hypertherm plasma cutters, elevating it above its competition. For example, when plasma cutting, a common tip you'll usually get from a seasoned cutter is, “Use a stand-off guide to better your movement and get a good distance off your metal.” With Hypertherm you don’t need that trick because the torches are designed to electrically isolate the nozzle from the metal, thus eliminating double arcing. Another tip that the SYNC machines took into consideration and made their own is “checking setting adjustments.” With the new consumables you don’t need to worry about it, because once attached, the machines read them and adjust them for you! The opportunities provided by the technology Hypertherm offers you in their equipment make the possibilities endless.

Get your Hypertherm SYNC plasma cutter and enjoy 3-day shipping! 

When it comes to plasma cutting, Hypertherm is a brand that is synonymous with quality, reliability, and innovation. With a range of plasma cutters and consumables that cater to different needs, Hypertherm has something for everyone, from industrial manufacturers to hobbyists working from their garages. In this blog post, we'll explore the reasons why you should consider a Hypertherm plasma cutter for your cutting needs.

Hypertherm Plasma Cutters: The Pioneers of Innovation

Hypertherm is a company that believes in pushing the boundaries of what is possible with plasma cutting. Their slogan "Shaping Possibility" is a testament to their commitment to innovation. Whether it's their patented consumables or their latest SYNC® plasma cutters, Hypertherm is always striving to make plasma cutting more efficient, versatile, and precise.

Versatility That Fits Your Needs

Hypertherm's range of plasma cutters and consumables is vast and covers a wide range of applications. From the industrial world to hobbyists, Hypertherm has a machine that fits every need. The SYNC® plasma cutters, in particular, bring a new level of adaptability to the playing field. With the ability to quickly and easily switch out consumables to fit your job application, you save time and money. These cartridges also take out the guesswork when it comes to traditional individual consumables such as shields, nozzles, swirl rings, and electrodes.

High-Quality Cutting at an Affordable Price

Investing in a quality plasma cutter is crucial for any cutting application, but it doesn't have to break the bank. The Hypertherm Powermax 30AIR is a plasma cutter that is both affordable and of high quality. This machine has an internal air compressor, making it easy to operate anywhere, and it can be plugged into any 120 or 240 V power source. Additionally, the torches that accompany every machine are also test-fired to ensure quality. If something were to go wrong, Hypertherm honors a 1-year warranty on the torch and a 3-year warranty on the power supply.

Industrial Solutions

In an industrial setting, Hypertherm's range of machines can tackle numerous tasks. Some of these consist of leg work for structural projects. Steel beams or columns for large buildings/structures can require some prep work, which is a fitting job for a Hypertherm SYNC® 105. This machine is also capable of multiple applications such as mechanized cutting, drag cutting, FineCut™, max control gouging, and FlushCut™, giving it high versatility in your workplace. In a sense of time, on most mild steels Hypertherm’s plasma cutting has a significantly higher cut speed than oxy-fuel. This not only saves time but also ensures high-quality cutting without compromising structural integrity.

Shop Plasma Cutters For Every Project At Arc Solutions

Looking for a reliable and high-quality plasma cutter for your next project? Shop our wide range of Hypertherm plasma cutters and consumables. With a commitment to innovation and versatility, Hypertherm has a machine to help you get the job done. Visit our website to find the perfect plasma cutter for your cutting needs!