The technology got its start in 1968 when company President Dick Couch and colleague Bob Dean mastered the concept of radial injection of water into a nozzle to create a narrower plasma arc capable of cutting metal with exceptional speed and accuracy.
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District sales manager Michael Vanvakaris recently answered a series of questions about the company and how its technology functions within the aftermarket realm.
To what extent has the international aftermarket industry embraced plasma-cutting technology in a repair shop environment?
Plasma-cutting technology is used in every major industrialized country in the world. Its adoption has come much faster in industries like shipbuilding, truck manufacturing and HVAC installation. Adoption in automotive repair has been slower, as many shop owners are familiar with the plasma cutters of yesteryear, which were large and expensive. The technology and cost have changed dramatically.
The most popular plasma cutter in the world today, the Powermax45, weighs 37 pounds, is rated for one-half inch cutting and can sever 1-inch thick metal, all at a starting list price of $2,160. Compare that with the typical machine just 15 years ago and it would easily be twice the power, size, weight and cost to do the same work.
We are seeing an explosion of interest in Europe, Latin America and even Asia as repair shops grapple with how to effectively cut the high strength metals used in cars today. We believe we are on the cusp of widespread adoption of plasma cutters by repair shops over the next two to three years as they realize how effective and affordable a plasma system can be for auto body repair. A plasma cutter will become a must-have tool for repair shops.
Powermax systems are used around the world — there are millions of them in use. Although all of our systems are built here in the U.S., a majority of our systems wind up in Asia (China, Korea, Japan, India and more); Europe (Russia, Poland, France, Germany, Italy and more); the Middle East (UAE, Saudi Arabia and more); and South America (Brazil, Columbia, Argentina and more).
How can the technology be applied for manufacturing aftermarket parts?
Most all plasma cutters are easily integrated into small or large CNC cutting tables and they are used daily in the automotive aftermarket to manufacture parts in production settings. One benefit of our systems is that they come with a patented quick disconnect system, which makes it fast and easy to switch out your torch (to move from a handheld torch to a mechanized torch.) It’s no harder than unplugging an electrical cord from the wall.
What is plasma?
Plasma is basically lightning channeled through a torch. It’s this intense amount of heat — many times hotter than the surface of the sun — that forms when electrical energy is applied to a gas. Plasma cutting systems use this intense heat to cut or gouge just about any kind of metal.
How does torch technology help with precision cutting?
Hypertherm devotes more resources to plasma research and development than any other company in the world. We take our torch technology very seriously, which is why we have several patents on not only our torches, but the consumables that go inside them.
One of the things we work on is making sure the arc is focused and stabilized very precisely in the center of the electrode. This helps to create a very dense arc and helps the consumables last longer to save you money.
Another example of our advanced technology is our new spring electrode. All other plasma systems use a moving plunger inside the torch to start the arc. Our newer systems don’t have this moving mechanism inside the torch, making our torches more reliable because there’s nothing to break and allowing us to make straight and other differently shaped torches.
How do your systems differ from cutting torches that come with welding systems?
The plasma arc is created using electrical energy and superheating standard compressed air (gas), then forcing this energy through a nozzle creating 28,000 to 30,000 degrees of focused heat. The cutting machine pinpoints the heat in a small area to create a small HAZ (Heat Affected Zone). In contrast, a typical oxyfuel cutting torch creates a flame by mixing a fuel gas, like acetylene and oxygen, to approximately 6,000 degrees. It also spreads this heat out across the surface of the material being cut, creating a large HAZ compared to plasma.
Why should I pay to get the Powermax system?
Hypertherm’s been in business since 1968, focusing our engineering on plasma cutting processes. It’s all we do, and we devote more resources to plasma research and development than any other company. As of right now, we have about 100 patents. We are not a “me too” company in that we don’t manufacture welding machines, battery chargers, etc. We only build metal cutting machines and, I might add, we only build them right here in the United States.
What are the cost comparisons to the welding tanks with torches vs. plasma cutters?
A typical oxy/fuel cutting torch system requires the following list of products to work:
- Oxygen Cylinder
- Oxygen Regulator
- Acetylene Cylinder or Comparable Alternative Fuel Cylinder
- Fuel Gas Regulator
- Dual Gas Hose-typically 25 feet’
- Oxy/Fuel Torch Mixing Handle
- Oxy/Fuel Cutting Torch attachment with Cutting Tip
- Cutting Torch Striker
- Cutting Torch Tip Cleaner
- Dual Cylinder Welding Cart
- Shade 5 Cutting Glasses
- Welding Gloves
That’s a dozen different things you need to get. Typically, the cost to buy all that from a welding supply company, and this includes purchasing the cylinders outright, is about a thousand dollars. So, you’ve spent a thousand dollars and you can only cut carbon steel and not any other alloys you often find on cars like stainless steel or aluminum.
The starting price for a good quality plasma system is in the $1,200 to $1,400 range. The only other thing you need to make it run is a compressed air source, which most shops already have, and power (electricity from a wall or a generator). So the initial cost to buy a plasma cutter is more than oxyfuel, but over time that plasma system is going to cost you less money and let you do more stuff. You can cut any metal, gouge any metal, get in tight corners, etc. and it is way safer.
Which product would be recommended for manufacturing?
The smallest machine we offer that can be integrated into a CNC cutting table is our Powermax45, which is a 45 amp machine capable of manufacturing 3/8-inch steel in small production settings. On the other end of our product offering , we offer a 400 amp machine capable of manufacturing 2- to 3-inch carbon steel in production settings. Obviously that’s way more than you need for a car, but I think it demonstrates just how powerful plasma is.
What are the environmental benefits of a plasma cutter in a shop environment?
Plasma cutting systems create less fumes and particulate smoke versus traditional oxy/fuel cutting torches. They also are much quieter, so it’s better for your ears and those working around you, and they are much safer to use.
For more information, visit www.hypertherm.com.
