High-Definition CNC Plasma Cutters

Table of Content

• Morgan Rushworth plasma range
• Ajan plasma range
• How does a plasma cutter work
• What is the result of adding CNC control
• Comparing plasma cutting machines to other forms of cutting
• What kind of plasma cutter do you need
• Single gas or high definition plasma
• Frequently asked questions
• Plasma maintenance
• Correctly maintaining plasma consumables

At Selmach, our range of CNC metal cutting plasma machines covers all possible production needs, from the smaller, more affordable plasma cutters up to top of the line, large scale production machines. We pride ourselves in being able to supply the best solutions for your unique needs regardless of budget, capacity or size.

Combine that with our first class after sales service and the ready-to-ship consumables your business demands and it is clear to see that our range of CNC plasma cutting machinery is more than an investment, it’s a partnership.

Our own Morgan Rushworth brand combined with the Ajan plasma offer the very best plasma cutting machinery, whatever your requirements.

Morgan Rushworth ECP Compact CNC Plasma Cutting Machine

Especially designed for simple but accurate cutting of sheet and plate material, the Morgan Rushworth ECP Compact CNC Plasma Cutting Machine is equipped with an intuitive operator friendly LYNCA-CNC controller supplied together with Libellula auto nesting software. The CNC controller provides access to the part programs, shape libraries and has a separate control interface which includes a joystick for jogging, start, stop etc. It is rich in functionality including full monitoring of the cutting process, in built library of parameters for common thicknesses etc. and the ability to change cut parameters for a part program once loaded onto the CNC.

Heavy-duty but ultra compact with class leading power

These heavy-duty models are equipped with the industry leading Hypertherm Powermax power source utilising single gas plasma technology. The result is a high quality machine, delivering low initial and operating costs, high productivity, superior cut quality and unsurpassed reliability.

The ECP has a very heavy-duty table and gantry with a compact bed size of 3 m x 1.5 m. It has a solid welded structure with the rack and pinion having a linear guidance system providing excellent accuracy and alignment. The rails are of a modern design which includes protection and distance from the cutting process ensuring longevity and accuracy. Available with an optional extraction system, or a water bed,

Technical Specification

• Hypertherm Powermax 45/65/85/105 plasma unit for single gas cutting
• Air or Nitrogen cutting
• Easy to use touch screen LYNCA-CNC controller
• Automatic torch height control
• Torch collision protection system
• Automatic ventilation and smoke extraction system ready to be connected to a filtration system
• Positioning speed 15 m/min
• Positioning accuracy +/- 0.01mm
• LMT 25mm high accuracy linear rail
• High quality Eisele gearbox
• ESA AC digital servo motors and drivers
• Gudel helical rack and pinion system
• Libellula auto nesting software

View the Morgan Rushworth ECP Plasma cutting machine

The Morgan Rushworth ACP CNC HPR High Definition Plasma Cutting Machine

Designed for ease of use and the best results, the Morgan Rushworth APC series of High Definition plasma metal cutters are fitted with intuitive, easy to use, Windows based Hypertherm MicroEDGE CNC controllers and a choice of power sources to tailor them perfectly to your business. Choose between the class leading Hypertherm Powermax power source utilising single gas plasma technology, the MAXPRO200 air/oxygen plasma source or the renowned Hypertherm HPR XD power source for multi gas high definition plasma cutting.

A cost-effective tailored solution

The ACP series comes in a range of bed sizes, 2 m x 1 m, 3 m x 1.5 m and 4 m x 2 m, The machines feature a moveable control panel, a zoned downdraft bed, a heavy duty linear guidance system and a unique torch access design. The Morgan Rushworth ACP CNC High Definition Plasma Cutting Machine has many class leading features that you might struggle to find in plasma cutting machines in a similar price range.

Optional extras include NestMaster automatic nesting software, TurboNest or ProNest nesting software and additional productivity modules, automatic gas console and extraction/filtration system.

Technical Specification

• Hypertherm HPR130XD high definition multi gas plasma source
• Hypertherm Nesting Software options
• Automatic torch height control
• Torch collision protection system
• Automatic ventilation and smoke extraction system ready to be connected to a filtration system
• Positioning speed 30 m/min maximum
• Positioning accuracy +/- 0.02mm
• LMT 25 mm high accuracy linear rail
• High quality Eisele gearbox
• Mitsubishi servo motor
• Atlanta rack and pinion system
• Moveable Control Panel with gantry control joystick

View the Morgan Rushworth ACP Plasma machine

'...a great addition to the workshop...'

Shipbuilders Intermarine

The Morgan Rushworth HDP CNC High Definition Plasma Cutting Machine

Ultra fast production and the very best dross-free finishes come as standard with the HDP series of plasma metal cutters, thanks to the advanced Hypertherm Hyperformance plasma unit.

The next level of CNC control

The Hypertherm MicroEDGE CNC controller is fitted as standard across the HDP series, delivering the potential to accept designs across many different formats such as DXF and DWG files, from a disk, CD, via the USB port or directly through an Ethernet connection. Alternatively standard shapes that have been preloaded can be edited and are dimensioned as required with the keypad control and visualised on the LCD screen

CNC tube plasma attachment and auto nesting software

Single, three and six station drilling heads are available for the HDP range which require EDGE Pro control. A bevel cutting plasma head is also available (reduces available bed width by 500mm), CNC tube plasma attachment and auto nesting software.Upgrade to Hypertherm EDGE Pro CNC control is available too. The Morgan Rushworth HDP series requires an extraction/filtration system, which can be supplied as optional equipment, or alternatively the machine can be connected to a new or existing factory ducted system.

Technical Specification

• HyPerformance High Definition plasma cutting technology for unmatched reliability
• Advanced XD technology with patented LongLife®, PowerPierce® and with optional equipment TrueHole™ capability
• Hypertherm automatic gas console
• Hypertherm torch height control
• Superior consistent quality dross free finish without the requirement for secondary operation
• Maximised productivity with minimised operating costs
• Electrical current and gas pressure applied in a gradual controlled manner at the beginning and at the end of the cut - six to eight times greater than comparable traditional systems
• High efficiency Hypertherm plasma unit and Windows based MicroEDGE Pro CNC controller to ensure perfect operational harmony
• Hypertherm ProNest 2012 nesting software
• 180mm touch screen LCD display
• Large range of standard table sizes, with special sizes available on request
• Strong steel frame designed to withstand constant high speed production
• X and Y axis travel on precision linear guide rails
• Fast positioning with Siemens brushless AC servo motor
• Positioning accuracy to 0.01mm
• Automatic torch ignition and height control
• Arc voltage feedback to control optimum torch height position
• Mechanical and electronic collision avoidance system
• Marking and cutting of material performed with the same plasma torch
• Torch can be set manually to bevel up to 45 degrees
• Fume extraction system beneath the table with exhaust connection at rear of machine that can be connected to factory extraction system or to optional filtration unit

View the Morgan Rushworth HCP CNC High Definition Cutting Plasma

The Morgan Rushworth HDPX Range of High-Definition CNC Metal Cutting Plasma

The Morgan Rushworth HDPX Range takes the innovative quality of our HDP plasma machines, the heavy duty reliability of the ACP series and combines them to create a premium High Definition metal cutting plasma with an outstanding pedigree of our wide range.

Available in table sizes from 1500 x 3000mm all the way up to 6000 x 36000mm depending on your individual needs, the HDPX series comes with Hypertherm MicroEDGE CNC control allowing simple choosing of parts from the library or external drive.

CNC Tube Plasma Attachment

The HDPX series can undertake tube and pipe cutting via the optional CNC tube plasma attachment along with optional single, three and six station drilling heads. A bevel cutting plasma head is also available to expand the bed width by 500mm, CNC tube plasma attachment, auto nesting software and potential upgrade to Hypertherm EDGE Pro CNC control can all be used with the HDPX range.

Technical Specification

• HyPerformance High Definition plasma cutting technology for unmatched reliability
• Advanced XD technology with patented LongLife®, PowerPierce® and with optional equipment TrueHole™ capability
• Hypertherm automatic gas console
• Hypertherm torch height control
• Superior consistent quality dross free finish without the requirement for secondary operation
• Maximised productivity with minimised operating costs
• Electrical current and gas pressure applied in a gradual controlled manner at the beginning and at the end of the cut - six to eight times greater than comparable traditional systems
• High efficiency Hypertherm plasma unit and windows based MicroEDGE Pro CNC controller to ensure perfect operational harmony
• Hypertherm ProNest 2012 nesting software
• 180mm touch screen LCD display
• Large range of standard table sizes, with special sizes available on request
• Strong steel frame designed to withstand constant high speed production
• X and Y axis travel on precision linear guide rails
• Fast positioning with Siemens brushless AC servo motor
• Positioning accuracy to 0.01mm
• Automatic torch ignition and height control
• Arc voltage feedback to control optimum torch height position
• Mechanical and electronic collision avoidance system
• Marking and cutting of material performed with the same plasma torch
• Torch can be set manually to bevel up to 45 degrees
• Fume extraction system beneath the table with exhaust connection at rear of machine that can be connected to factory extraction system or to optional filtration unit

View the Morgan Rushworth HDPX Range of High-Definition CNC Metal Cutting Plasma

The Morgan Rushworth SPM CNC Tube & Section Plasma Machine

The Morgan Rushworth SPM Tube Plasma profiling system is a highly innovative machine combining the low-cost benefits of mechanised air plasma cutting with CNC automation and nesting. With the ability to profile up to 300mm diameter round tube at 12 metres long, the SPM has the capability for most common tube working requirements.

Combined with the durable and recognised Hypertherm Powermax system, the SPM automates many manual processes into one seamless CNC designed and controlled cutting operation.

Multi Part Nesting

Nest and cut multiple different parts from a single tube or piece of section for optimal efficiency. Simply program your required cuts, and the machine handles the rest.

Technical Specification

• Multi part nesting on a bar for optimised material usage
• Removes many traditional manual functions – sawing, cropping, grinding, notching, punching, drilling etc
• CNC accuracy; No errors or need to rework
• Tube Plasma cutting capability up to 12m length x 300mm diameter
• Hypertherm Powermax Plasma Source 45a – 105a
• Automated 4 Jaw Chuck Clamp & Feed carriage assembly from 3 to 12 metres
• Linear motion & rack & pinion movement
• Fully automated cutting process
• Centralising through-feed chuck at cutting station
• 12″ Touchscreen CNC Control allowing import and storage of cut files plus design of cut parts on the control
• Fully CE protected operation cabin using Light beams
• Engraving & Marking features available
• Automatic Torch height control
• Automatic Pipe Support on infeed
• Data import by USB & network

View the Morgan Rushworth SPM CNC Tube & Section Plasma Machine

...The cutting capacity and quality have exceeded our expectations...

J.Silk Agricultural

The Ajan High-Definition Metal Cutting Plasma

Crafted by Ajan, international market leaders known for quality, reliability and their ethos of creating every component (including consumables), in-house to guarantee quality the Ajan High Definition Plasma combines reliability, affordability and the best industrial heavy duty standards.

Heavy duty finesse

Constant high speed plasma cutting across a range of materials and thicknesses is easy with the Ajan Plasma. Each machine features a strong steel frame construction with waterbed as no cost option. There is also the option of a heavy industrial extraction/filtration system (machine can also be connected to factory extraction system) meaning a cleaner working environment. The bridge and rails being separate from the machine bed, means that there is no heat transfer from the plasma machine bed to the bridge, improving accuracy.

The Ajan range of metal plasma cutters come with Ajan CAD/CAM software including comprehensive features and free software upgrades as standard.

Oxy Cutting Torches & Filtration

Options include the advanced bevel cutting plasma head, oxy cutting torches and a heavy duty industrial extraction/ filtration system, developed specifically for these models; alternatively they can be connected to a new or existing factory ducted system. 4 & 5-axis bevel cutting heads are also available.

Technical Specifications

• High Definition plasma cutting technology
• Automatic gas console
• Automatic torch height control
• Ajan CNC control unit using industry standard DIN/ISO ‘G’ codes
• Able to work with DXF, ESSI and NC toolpath files
• CAD drawing software
• CAM nesting and optimisation software
• Consistent quality, virtually dross free finish without the requirement for secondary operation
• ‘Optohole’ technology for bolt hole optimisation
• Strong steel frame designed to withstand constant high speed production
• X and Y axis precision rack and pinion system with AC servo motors
• Resume cutting feature
• Rapid traverse speed
• Marking and cutting of material performed with the same plasma torch
• Fume extraction system beneath the table with exhaust connection at rear of machine that can be connected to factory extraction system or to optional filtration unit

View the Ajan High-Definition Metal Cutting Plasma

How a CNC plasma cutter works

We are familiar with matter. It is the generic scientific name for ‘stuff’ and, in our day to day lives, we come across matter in three different states. Water is a great example. On a cold day we might come across ice, so that would be solid matter. On a rainy day we might get soaked by water in a different state, as a liquid. If we make tea and boil water to do so, the steam from the kettle is water that has entered a gas phase.

Solids, liquids and gases are the three main states of matter, but plasma is known as the fourth state of matter.

We don’t come across plasma very often in our daily lives compared to solids, liquids and gases, due to the very specific and unusual circumstances in which plasma is formed. Energy is applied to water to create steam, if much more energy is applied to steam then its component atoms become ionised and electrically conductive. This is plasma.

The Plasma cutting machine works to create these conditions using a control, a power supply, a torch and an arc starting circuit to provide the electrical energy and ionisation which deliver very high quality, highly efficient cuts through any conductive material.

The plasma is passed through a very constricted opening, known as the nozzle, causing focused acceleration of the gas. This gas and the high speed of travel through the material are what create the cutting process.

What is the result of adding CNC control to a plasma cutter?

CNC plasma cutters offer exactly the same high quality efficiency of cutting power as standard machines but with the addition of computerised control.

The CNC (Computer Numerical Control) brain of the plasma cutter relies on the combination of hardware and software and programs to save designs and carry out even the most complex cutting tasks quickly and to a very high standard.

CNC plasma cutting machines can vary in size, functionality and cost but all are fast, with the potential to cut up to thirteen metres of metal per minute. To accomplish that, they need gases to form the plasma and assist it and these will vary depending on the types of material being cut. Compressed air is commonly used in lower current plasma cutters and on thinner materials but other gases such as argon, oxygen and nitrogen can also be used. Some machines have dual or multi-gas systems for a wider range of applications with the CNC control automatically selecting the correct gas for each operation.

Comparing CNC Plasma cutting machines to other forms of cutting

CNC Plasma cutters carry a range of benefits over other cutting methods such as laser and waterjet cutting machines. Plasma cutting can be carried out to a high standard with minimal training and experience compared to other forms of cutting as complicated adjustments are kept to a minimum.

Plasma is also ideal for a wide range of both ferrous and non-ferrous metals, for example, steel, copper and aluminium, and for materials of varying thicknesses. If the material is over 3mm thick it is also a significantly faster cutting method than laser or waterjet.

For a more in-depth look at how the plasma cutting process and the machinery involved compares to other methods such as Laser and Waterjet, have a look at our article here exploring the different applications and the unique characteristics of each.

What kind of cnc plasma cutting machine do you need?

The decision to invest in a plasma cutting machine, like all other machinery involves considerable thought. Capacities, cost and the type of work you do, or perhaps want to do in the future, are all important factors.

At Selmach, we offer a diverse range of plasma cutters which can be seen and demonstrated at our national showrooms.

Compact machines such as our Morgan Rushworth ACP series come in bed sizes from 1m x 1m up to 1.5m x 3m. These compact powerhouses are ideal for cutting thinner materials, for tasks such as ductwork or light fabrication duties. They come with a Hypertherm power source which can handle steel up to 25mm thickness with ease. A waterbed is standard, avoiding the additional cost of extraction equipment.

Next up is the excellent Ajan CNC plasma cutter range….

We’re talking about a top quality, heavy duty machine here. The Ajan plasma machines are constructed with a strong steel frame, designed to cope with constant usage. Bridge and rails being independent from the machine bed means that there is no conducted heat transfer from the plasma head down onto the bed or vice versa and loadings from heavy material placed on the bed don’t affect the bridge and rails.  These machines offer high-quality profile cutting, with a pristine, virtually dross-free finish and excellent edge squareness. With the Ajan plasma cutter all CAD/CAM software is included and software upgrades are free. Everything is made by Ajan themselves resulting in economical consumables and good availability of spare parts when needed. Other features and benefits include an automatic gas console, automatic torch height control, ‘Optohole’ technology for bolt hole optimisation, advanced 5axis bevel cutting torch head, and oxy cutting torches.

Our mid-range Morgan Rushworth ECP and ACP models are well suited to medium sized fabricators with bed sizes from 1.5m x 3m. They are capable of handling steel up to 45mm thick thanks to their Hypertherm power source. They are also compact, making them ideal for smaller workshops.

Our Morgan Rushworth HDP and HDPX plasma cutting series will win if genuine heavy-duty automation is your goal. They have excellent capacities up to 4m x 12m in length as well as the latest Hypertherm XPR power source and a range of options, including CNC drilling, that allow you to tailor your machine to your own unique needs.

Single Gas or High Definition CNC Plasma cutter?

As well factors such as CNC automation and capacities, thought must be given to whether a single gas plasma machine or High Definition plasma would better suit your needs. Single gas plasma cutting machines fill an important role in fabrication offering the benefits of conventional plasma and the savings that come from this more budget friendly option. Certainly for one-off jobs and those occasional times when large scale work is needed, particularly with thinner materials, single gas plasma can often be the best option. See our knowledge base article dedicated to single gas plasma cutters to help you decide if one might be right for you.

High Definition plasma however, has the potential to do much more as our knowledge base article shows in greater depth. Cut quality and productivity are both impressive. Material thickness limitations are reduced too, with these machines delivering superior cutting power, a greater degree of control and less dross. Edge bevelling is also an option with a 5axis torch. For a more in-depth look at plasma cutting machines and which might be right for you, our article and visual guide can be found here.

Frequently asked questions for CNC plasma cutters

At Selmach, we come across a range of questions regarding CNC Plasma cutting. Here are some of the most frequent.

What gases will I need for plasma cutting?

Air, nitrogen, oxygen, hydrogen, argon; each is used in plasma cutting and each is best suited for certain materials. Aluminium over 12mm thick, for example, is best cut with an argon hydrogen mixture to avoid oxidisation and preserve edge quality. Thinner aluminium can be cut with air. There is always a balance to be struck between the price of gas and cut quality and speed. Gas suppliers provide a wealth of information to guide your decisions.

Machines with dual or multi gas capability, have the versatility to work with a range of plasma and shield gases as determined by their cutting needs.

What can I cut with plasma?

In short, any material that is electrically conductive can be cut with a plasma cutter. That includes cast iron and copper.

How hot is the plasma created by a plasma cutter?

Incredibly hot, around 20,000 degrees Celsius and its velocity approaches 750mph.

How long do plasma consumables last?

That can depend on a range of factors such as material thicknesses and cutting speeds, as well as the amperages you use. Correct machine settings will preserve consumable life. Generally, it is a good idea to replace the two main components at the same time.

Nozzle

The Nozzle constricts the arc and focuses the plasma onto the material. It is subjected to constant heat despite being cooled by the gases passing through it. Over time the nozzle opening might show signs of wear characterised by a misshapen hole.

Electrode

The Electrode carries the current from torch assembly to the workpiece and over time the conductive elements turn molten and exit out of the nozzle during the cutting process, forming a pitted hole at the electrode’s front and sometimes causing the plasma to glow green as all the conductive elements have blown off. Cutting at this stage is seriously compromised and other components placed at risk.

Swirl Ring

The Swirl Ring swirls the plasma gas to keep it cool, to focus the arc and keep it centred on the electrode. It is designed to cope with constant heating and cooling, making failure because of these factors uncommon. Issues are more likely to be as a result of drops and knocks. As a general rule, replace swirl rings after every 5-10 sets of electrode and nozzle replacements.

Shields

Shields and retaining caps are also at risk of damage from drops and knocks but generally tend to need replacing much less than electrodes and nozzles. Checking for slag build up on the shield is important to prevent constricted gas flow.

For a more in depth guide on components and when to replace them see our knowledge base guide dedicated to the topic.

Correctly maintaining your CNC plasma cutter consumables

Well maintained plasma consumables deliver the best possible results and last longer, saving you and your company time and money.

There are a number of things you can do to ensure your plasma consumables deliver the service and longevity you need. We have a detailed breakdown as part of our knowledge base series; here are some of the most important points.

• Cutting speed is a real factor and balance is important; try to cut too fast and you won’t cut at all; cutting too slow risks placing unnecessary strain on all your consumables, meaning shortened life and quicker burnouts
• Making sure your hands and PPE are clean is important but often overlooked. Handling the electrode and other consumables with greasy hands can cause issues with stray tracking and problems with cooling
• Don’t over tighten. Electrodes have an O-ring seal, meaning when you feel the locating shoulder touch the bottom of the torch, it is installed correctly. Tightening it further risks expensive damage and unnecessary downtime
• Measure your electrode’s pit depth with a dial indicator. If it is more than 0.8mm replace it ASAP. Neglecting to do so can lead to serious failures that can damage other components, and certainly the rest of your consumables
• Always pierce your work piece from the recommended height, to preserve your nozzle and to avoid it being contaminated with workpiece material
• Don’t try to match up your consumables with non-compatible brands. Make sure your swirl ring and all your other consumables match your application