4 Hypertherm Plasma Cutters Compared – What You Need to Know

When it comes to metalwork, plasma cutters have the ability to make easy work of what was once a tedious task. They can cut through a variety of metal thicknesses making the instruments useful for various applications. It makes sense, then, that if you’re in the market for a precision instrument that is made by one of the most trustworthy brands in America and don’t mind paying a little more, Hypertherm will have the right product for you.
Plasma Cutters Amps Weight Price Buy Now
Hypertherm Powermax 30 XP Plasma Cutter 30 Amps 29.8 Pounds $$$ Check Prices
Hypertherm Powermax 45 Plasma Cutter 45 Amps 37 Pounds $$$ Check Prices
Hypertherm Powermax 65 Plasma Cutter 65 Amps 64 Pounds $$$$ Check Prices
Hypertherm Powermax 85 Plasma Cutter 85 Amps 71 Pounds $$$$$ Check Prices

The Best Hypertherm Plasma Cutters consist of extremely portable air plasma systems that allow users to tackle any job involving electrically conductive metal by hand or with machine-driven cutting. In this review we’ll take a look at some of the top Hypertherm Plasma Cutters in order to assist you in selecting the best options for you.

If anything goes wrong, the Hypertherm Powermax plasma cutters have a 3 year warranty (2 years on power supplies and 1 year on torches and leads). That is pretty good compared to other brands.

Hypertherm Plasma Cutter Reviews

1. Hypertherm Powermax 30 XP Plasma Cutter Review

Editor’s Rating:” alt=”4.5 out of 5 stars” />

  • 30 Amps
  • 29.8 Pounds
  • $$$

This Hyperthem Plasma Cutter is designed to deliver high performance in a small, portable unit. At 21.4 pounds and with dimensions of 14″x5.5″x11.5″, it’s easy to see portability is not an issue. It has a two-in-one arrangement that provides a high-powered ability to cut thicker metal pieces plus is able to detail thin metal sheets. Adapter plugs are available for either 120 or 240 v circuits and the output of the unit is 15-30 amps.


It’s the perfect option for light industrial workers as well as for home hobbyists in that it utilizes internal compressed air for power. Beginners and weekend warriors will find it super easy to learn to use. In fact, it can be up and running within a couple of minutes. Unfortunately, it is designed to cut thinner conductive materials up to 3/8″ on a 20 amp breaker. However, for most smaller jobs it’s the ideal choice.

2. Hypertherm Powermax 45 Plasma Cutter Review

Editor’s Rating:” alt=”4 out of 5 stars” />

  • 45 Amps
  • 37 Pounds
  • $$$

This plasma cutter is considered somewhat vulnerable by users so Hypertherm created a 45 XP for those that don’t mind paying a little more for more reliability, but here we’ll focus on the 45. The Hypertherm Plasma Cutter Powermax 45 is a 1/2″ system with broad capabilities and 20-45 amps of cutting power. The torch technology allows users to cut 1/2″ thick metal and severs up to 1″. It’s 16.75″x6.75″x13.7″ and weighs only 35 lbs.

The Powermax 45 is an especially good choice for those that intend to use it to make precision cuts with certainty. The good thing is that it’s less expensive than other options. Additionally, for those without an air compressor, nitrogen gas works just as well and is less expensive. It’s especially good for people that work as metal artists or sign manufacturers as well as those with trades such as metal building construction, auto repair, pipeline jobs or farm repair. Along with its precise cutting, it is also easy to use and understand.


3. Hypertherm Powermax 65 XP Plasma Cutter Review

Editor’s Rating:” alt=”5 out of 5 stars” />

  • 65 Amps
  • 64 Pounds
  • $$$$

The Hypertherm Powermax 65 cutter has several advantages over other models such as Smart Sense Technology that automatically adjusts the gas pressure while the unit is engaged. Greater versatility is added with 7 Duramax torch styles so the right tool can be selected the first time. A faster cut speed, longer expendable life and an improvement on the cut quality means lower operating costs.

The Powermax65 has greater portability than previous models, weighing only 64 lbs, and being 19.7″x9.2″x17.9″. The output current is 20-65 amps meaning it will cut smoothly through mild steel, stainless steel and aluminum. The conical flow nozzle increases the arc energy density and a patent pending shield reduces dross buildup. Users have reported that the units reliability guarantees optimum execution even when working in the roughest environments.

4. Hypertherm Powermax 85 Plasma Cutter Review

Editor’s Rating:” alt=”5 out of 5 stars” />

  • 85 Amps
  • 71 Pounds
  • $$$$$

One of the Best Hypertherm Plasma Cutters is the Powermax85. It has the same options and features as the Powermax65 but with more power from the output current of 85 amps. Hand cutting and gouging, robotic cutting or gouging, exceptional versatility and X-Y table are achievable with an array of Hypertherm Duramax torch styles. It has been designed to eliminate the need to change the air pressure due to Smart Sense Technology.

On mild steel it cuts 250% faster up to 1″ thick than equipment that requires the use of Oxyfuel. With a 7.6m torch the CSA model weighs 71 lbs and the CE model weighs 62 lbs. And, when it comes to size it measures merely 19.7″x9.2″x17.9″. It also runs on either oil-free air or nitrogen. The Hypertherm Powermax 85 is the perfect hand-held plasma cutter for longer cutting jobs. Its heat resistant handles prevent overheating of the unit. Best of all, the control panel also features an LCD output screen making the operation extremely easy.


One of the portable Powermax Hypertherm Plasma Cutters will be just right for any cutting job you may be tackling. The thickness of the metal to be cut, whether a hand-held torch or automated machine will be used, the electrical service you’ll be using and the engine drive generator the system will be powered by are important considerations that should guide your decision. The best part is that even beginners can easily operate any of the Powermax Systems and produce top quality products on-time and more profitably.