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Best Plasma Cutter for Auto Body Work- 5 Top-Rated Models

Have you been spent hours looking online for the best plasma cutter for auto body work?

Well, then this is where you should stop!

If your work involves restoration or repairing the auto body, there are always some pieces of metal that require cutting. You can get the job done with an angle grinder, air-powered nibble, or hacksaw. But a plasma cutting machine will save you energy and time.

Plasma cutters can cut painted and rusty metals with use and are great for working in tight quarters on floor panels or irregular cutouts. Moreover, a plasma cutter won’t heat warp the metal.

After looking through the ranges of products available in the market, I’ve enlisted 5 top-rated auto-body plasma cutters from the best brands in the industry.

Scroll down to discover them!

Best Plasma Cutter for Auto Body Work- In-Depth Reviews of 5 Models

best plasma cutter for auto body work
Best plasma cutter for auto body work

If you’re a hobbyist or automotive professional, a plasma system is a must-have for automotive metal cutting.

For custom car builds, vehicle restoration, or repair, a lower amperage plasma cutter can work fine. A low amp unit provides you with more fine-tuned adjustments in lower settings. It reduces the amount of heat absorbed and prevents metal from warping.

Here are our experts’ recommendations for the best plasma cutters for auto body work enthusiastic, either a professional or a hobbyist.

These units are user-friendly, high quality, durable and affordable. To cut vehicle bodies, frames and other metal parts, any of these 5 models can be a significant investment.

‎#1 HEROCUT CUT45-110V Plasma Cutter

herocut cut45 plasma cutter

Specs

  • Arc starting: Touch metal
  • Max cutting thickness: 12mm#110V 60PSI (0.5Mpa)
  • Cutting speed: 150mm/min at 8mm thick metal 60PSI air pressure
  • Rated input capacity: 4.5 KVA
  • Input voltage: AC110V+/-10% 50/60Hz
  • Current range: 15A-40A
  • Duty cycle: 70%
  • Efficiency: 85%
  • Air Demand: 1.5cfm
  • Insulation class: F

Are you looking for the best plasma cutters for professional auto mechanics?

Whether you are a professional or DIY hobbyist, HEROCUT CUT45 is a good choice to work on your car. It is a high-frequency 50/60Hz IGBT Inverter air plasma cutter.

HEROCUT is a trusted brand name in the plasma cutting and welding industry. This company is well-known for providing high-quality welding products. HEROCUT CUT45 IGBT plasma cutting machine is no different.

Why Choose HEROCUT CUT45 plasma cutter?

110V single-phase

This 110V plasma cutter is more efficient and durable than most machines.

Impressive cutting thickness

HEROCUT classic red machine provides a clean cutting thickness of 8mm and a maximum cutting thickness of 12mm at 110V 60PSI (0.5Mpa). It is efficient to cut stainless steel, Alloy steel, mild steel, Copper, etc.

Excellent internal structure

The strong casing and internal components on this machine make it perfect to use in harsh garage conditions.

Quiet operation

HEROCUT CUT45-110V is relatively quiet compared to air chisels, grinders, and sawzalls that are usually noisy tools for exhaust work.

Package Includes:

  • Plasma cutting machine (1)
  • 4 meters cutting torch (1)
  • Earth clamp with cable (1)
  • Air filter (regulator) (1)
  • Air Hose (1)
  • Electrode (2)
  • Tip (Nozzle) (2)
  • User’s manual (1)

Pros

  • Well-made and heavy-duty
  • Precision internal construction
  • Fast easy to learn to use
  • Powerful performance
  • Simple to operate
  • Strong cutting performance
  • Well priced
  • Lifelong after-sales service

Cons

  • It can only be used at 110V voltage.

FAQs About HEROCUT CUT45-110V?

  • Does this unit work with 120V?

110 volts is no different than 120 volts. So, it will work on a 120-volt circuit too.

  • What size air compressor do I need to operate this 110V single-phase plasma cutter?

You’ll need an air compressor that can supply 5L/min (maybe 2-5KW).

  • What type of eye protection do I need during using this plasma cutting machine?

You can use ordinary laser protective welding lenses. It mainly prevents strong light and splash.

#2 hynade HYC45D Plasma Cutter, 115/230V

hynade hyc45d plasma cutter

Specs

  • Arc starting: Touch metal
  • Quality Cutting Thickness: 6mm@60PSI
  • Severance cutting thickness: 10mm@70PSI in 230V
  • Rated input capacity: 4.5 KVA
  • Input voltage: AC 115V/230V
  • Input Current: 45A(115V), 35A(230V)
  • Output Current: 30A(115V), 45A(230V)
  • Output Voltage: 90V(115V), 96V(230V)
  • Duty cycle: 60% in 45A, 100% in 30Amps
  • No-Load Voltage: 260V
  • Air Compressor Flow: 45L/min
  • Earth Cable Length: 2 meters
  • Torch Length: 4 meters PT31
  • Generator Input: 3.9 KVA
  • Insulation Class: F

Hynade is a high-level brand focusing on the welding business for more than 20 years. hynade ‎HYC45D 115/230V inverter metal plasma cutter is a reliable, and durable dual voltage plasma cutter. It comes equipped with features that you expect from a quality plasma cutter.

Why Choose hynade HYC45D?

Powerful to cut various metals

This 40A unit is very good to cut car steel (frame). It works great for cutting stainless steel, 2mm thin Copper, Alloy Steel, 4mm Aluminum, Mild Steel, etc. You can use it for studio and outdoor work.

Easily cut different thicknesses

It offers a quality cutting thickness of 6mm and a Severance cutting thickness of 10mm@65PSI 40A 230V.

Adopt IGBT soft watch technology

IGBT soft watch technology makes the unit very compact and lightweight. It weighs only 6.3 kg (14.3 pounds).

Package Includes:

  • Plasma cutter (1)
  • Earth cable with 2 meters cable (1)
  • Cutting torch with 4 meters cable (1)
  • Air regulator with air gauge (1)
  • Tip (2)
  • Electrode (2)
  • Air hose with 2 pcs hose clamp (1)
  • Power plug wire (230v female to 115v male) (1)
  • Manual (1)


Pros

  • Reliable and robust
  • Super easy to operate
  • Efficient for cutting car steel (frame)
  • Smooth cutting surface
  • Compact design and very lightweight

Cons

  • The instruction book/manual could have been better.

FAQs about Hynade HYC45D 115/230V

  • Will this model automatically switch back and forth from 115 to 230?

Yes, this unit can automatically identify the voltage and switches back and forth. However, I recommend switching it off when changing the voltage, then turning it on again.

  • What consumables work best for this torch?

Any consumables that fit a PT-31

  • What is the thickest carbon steel I can cleanly cut with this using 230volt?

HYC45D’s thickest clean-cut thickness is 6mm.

#3 FLARING ‎FC500D Plasma Cutter, 50 AMP, 110V/220V

flaring fc500d plasma cutter

Specs

  • Arc starting: Touch metal
  • Torch: pt31 torch
  • Ideal Clean cut thickness on 110V: 1/3″(8mm)
  • Ideal Clean cut thickness on 220V: 1/2”(12mm)
  • Max. Severance cutting thickness on 110V: 3/5”(15mm)
  • Max. Severance cutting thickness on 220V: 2/5″(10mm)
  • Input voltage: 110/120 v 220/240 ac-dc
  • Max Current: 50A
  • Air Demand: 1.4 CFM
  • Suggested Air Pressure: 60-70PSI
  • Breaker Recommendation: 50A on 110V,30A on 220V

FLARING FC500D inverter plasma cutting machine is pretty amazing for the price. It comes complete with everything needed. It is a good choice for car frames, stainless steel, carbon steel, thin copper, aluminum, etc.

Why Choose FLARING ‎FC500D?

Automatic dual voltage

The 110V/220V voltage conversion cable can detect the voltage automatically when you plug it in and switch without any problem.

1/2” Clean Cut, Max 16MM

FLARING ‎FC500D cuts clean. It can be a much better alternative to using the grinder. It uses non-hazardous compressed air to cut Car Frames, Stainless Steel, Aluminum, Thin Copper, chrome, mild steel, cast iron, etc.

3 high-power large capacitors & 4 rectifiers

The power is larger and the unit is more stable.

Post Time Adjustable

The unit has pre-set 3 seconds of blowing time after the torch is released. This feature helps to cool down the consumables and torch head. In addition, you can set the blowing time by adjusting the knob. Conveniently, this unit comes equipped with an industrial cooling fan that helps to improve the duty cycle.

Handle for portability

This IGBT high-frequency inverter plasma cutting machine is compact and includes a handle to easily carry it around. So, you can use it anywhere.

Package Includes

  • Pressure connector
  • Raw tape
  • Consumables
  • Pressure holder
  • Pt31 torch
  • Fc-500d
  • Voltage conversion
  • Air regulator
  • Ground clamp
  • Hose & Hose clamp

Pros

  • Stable and powerful
  • Excellent quality
  • Simple to set up and operate
  • Lightweight and portable
  • Affordably priced
  • 3-years of product quality service

Cons

  • Not for commercial or heavy-duty uses.

FAQs about FC500D

  • Does this unit require shielding gas?

No shielding gas is required. It requires air for cutting.

  • Does this plasma cutter work on a 30 amp breaker?

Yes, it requires a 30A breaker for 220V and 50A for 110V

  • Can FC500D be run off a generator?

Yes, it should be 5000W or above.

#4 FLARING FL550D Non-Touch Pilot Arc Plasma Cutter, 50 AMP, 110/220V

flaring fl550d non-touch pilot arc plasma cutter

Specs

  • Arc starting: Non-touch metal
  • Torch: AG60 non-contact torch
  • Ideal Clean cut thickness on 110V: 1/3″(8mm)
  • Ideal Clean cut thickness on 220V: 1/2”(12mm)
  • Max. Severance cutting thickness on 110V: 3/5”(15mm)
  • Max. Severance cutting thickness on 220V: 2/5″(10mm)
  • Input voltage: 110/220V 50/60Hz
  • Max Current: 50A
  • Air Demand: 1.4 CFM
  • Suggested Air Pressure: 60-70PSI
  • Breaker Recommendation: 50A on 110V, 30A on 220V

If you’re looking for a non-touch pilot arc Flaring plasma cutter, FL550D is a perfect choice for you.

This well-built plasma cutter is perfect for DIY users, and professionals alike.

Why Choose FL550D Non-Touch Pilot Arc Plasma Cutter?

AG60 non-touch cutting torch

AG60 torch cuts the metal without touching the surface making the unit efficient for cutting rusty, rough, and painted metals. It cuts faster, and more efficiently than a touch arc plasma cutter.

It also produces minimal slag and provides a longer consumable life.

Cuts any electrically conductive metals

FL550D can cut any kind of electrically conductive metal. It efficiently cuts the thickness of 1-2mm up to 1-2 inches (sheet metal).

You can use this unit for cutting aluminum, brass, carbon steel, copper, mild steel, stainless steel, and expanded steel.

High-frequency transformer

The 110V/220V voltage conversion cable can automatically detect the voltage and switch automatically. The conversion line is easy to transfer from input 110V to 220V.

Built-in safety protection

FL550D has under-voltage protection, over-voltage protection, and over-heat protection. It has 3 high-power large capacitors and rectifiers that makes the unit more stable.

Package Includes:

  • FL-550D plasma cutter
  • AG60 torch
  • Ground clamp
  • Raw tape
  • Regulator & regulator holder
  • Wrench
  • Hose & hose clamp
  • Consumables
  • Voltage conversion

Pros

  • High cutting speed
  • Smooth cutting performances
  • Well-thought and safe design
  • Energy-saving and noiseless operation
  • Comes complete with everything needed
  • 2 year’s warranty
  • Pretty amazing for the price

Cons

  • Several customers have complained about missing part on the package.

FAQs FL550D plasma cutter?

  • How long is the torch lead and the earth clamp?

The torch lead is 13ft and the ground/ earth clamp is 5ft.

No. It’s just a non-touch pilot arc plasma cutter.

  • Does FL550D come with any warranty?

Yes, this model provides a 1-year warranty.

#5 ZS- MICTEK ‎Plasma cutter (Model: ZS-CUT45D1-US)

Specs

  • Arc starting: Touch metal
  • Torch: PT31
  • Ideal Clean cut thickness: 1/2”(12mm)
  • Max Cutting thickness: 15mm
  • Input power voltage: 110/220V, 50/60Hz
  • Rated input current: 40 to 45
  • Rated power capacity (KVA): 4.3 to 6.5
  • Air Pressure: 60-70PSI
  • Current adjustment range: 20 to 45A
  • No-load voltage: 300+/-20
  • Rated duty cycle: 60%
  • Efficiency: 80%
  • Power factor: 0.7
  • Protection class: IP21S
  • Plug Format: ‎A- US-style
  • Insulation class: F

CUT45D1 is a touch arc, portable plasma cutter which is perfect for both hobby/ home use and construction/ industrial work.

Why Choose ZS-CUT45D1-US?

Cutting Capacities

It uses non-hazardous compressed air to cut car frames, aluminum, mild steel, alloy steel, stainless steel, cast iron, copper, and chrome.

Carbon steel max 12 mm, stainless steel max 12mm, Aluminum 8mm, Copper 4 mm @110V
Carbon steel max 15 mm, stainless steel max 15mm, Aluminum 10mm, Copper 6 mm @220V

Upgraded Plasma Cutting Torch-PT31

PT31 torch is upgraded from heat-resistant rubber and cloth to fire-resistant material. It features a high-quality pure copper exquisite gun tip, that increases cutting efficiency to 2X. In addition, the length of the torch has been upgraded from 9ft to 16ft.

Auto Dual Voltage

ZS-CUT45D1-US has simple panel settings and automatic dual voltage 110/220V. It adapts to switch input power; no external conversion plug is required.

It also comes equipped with a high-frequency magnetic ball transformer, a newly upgraded large capacitor, and an original IGBT.

Perfect for Metal Art

It offers a smooth cut, so you can use it to create artistic patterns in metals. It is also one of the best plasma cutters for metal art for the DIY person.

Portable Handle

With a portable handle, CUT45D1 is very convenient to operate and carry from the job site to the job site.

Package Includes

  • Plasma Cutting Machine (ZS-CUT45D) (1)
  • Plasma cutter torch (5m) (1)
  • Earth clamp with cable (2m) (1)
  • Conversion line (20cm) (1)
  • Air hose (3m) (1)
  • Leak-proof tape (1)
  • Electrode (2)
  • Nozzle (2)
  • Hose clamp (4)

Pros

  • Easy setup and use
  • Very little to do to start cutting
  • Compact & portable design
  • Auto voltage adaption
  • Comes a complete set of accessories

Cons

  • Not for everyday use

FAQs about ZS-CUT45D1-US

  • What size breaker is recommended for a 110volt plug-in?

ZS-CUT45D1-US supports 110V and 220V input voltage. Make sure the power supply voltage is 110V+/-15% or 220V+/-15%. You’ll need a 50A breaker for when 110V plugin and a 30A breaker for the 220V plug-in.

  • Can I run this on Generator?

Yes. Make sure the generator is not less than 6000W.

  • Does this model work for metal work or precision artistic application?

Yes, ZS-CUT45D1-US gives you detailed cuts just make sure your metal is clean. However, cutting designs take a little practice and it depends on your steady hands. However, if you’re slightly artistically inclined, you can earn money with a plasma cutter from home.

How to Choose the Best Plasma Cutter for Auto Body Work

While buying a plasma cutter for auto bodywork, check for several must-have features or factors.

Let’s find the factors.

Quality

Choose a plasma cutter that is of high quality. Never compromise on the quality just for a little price concession.

If you need to use your unit on regular basis, it is wise to invest in a high-quality model that has a longer lifespan and warranty.

Plasma Cutting Torch

Make sure its plasma torch is highly efficient so that it can offer the best cutting performance.

For professional uses, you may need various torch heads for different purposes such as a nozzle, retaining cup, shield, and a swirl ring.

Cutting capacity, Thicknesses, and Speed

You may likely work with various types of metals and thicknesses during auto bodywork. It is convenient if the same plasma cutting machine can work for a range of metals and can cut different depths. In addition, make sure the unit offers the rapid cutting ability for a more precise cut.

Power Output

Power output has a direct impact on the ability of a plasma cutter to handle a wide range of metal types. Most units come with a 30 to 50amp range. The higher the rating, the heavy-duty the unit is.

If you need a plasma cutter for handling DIY projects, a 30 amp plasma cutter will be perfect.

Good Heat Dissipation Features

During the cutting process, the unit generates a lot of heat. Check for the cooling system of the unit and good heat dissipation features. A plasma cutting machine with a good cooling system allows you to work for longer times with greater accuracy.

User-friendly

Your plasma cutter needs to be easy to set up and operate. An easy-to-operate unit will allow you to handle it easily even if you’re a hobbyist or a first-time user.

Weight & Portability

Your plasma cutter needs to be lightweight and portable if you need to carry it around, especially if you work on a car’s auto body. It is easier to work with the unit if you can move it without any hassle. A lightweight unit with a top-mounted handle would be the best option if portability is a concern for you.

A 30amp plasma cutter weighs about 30 pounds. But a 45 amp or 60amp unit will be heavier and you may need a cart to move it around your garage.

A plasma cutter can help you tackle a wide range of metal cutting tasks in custom car builds. By selecting the right model and following plasma cutting tips, you can achieve better fit-up and quality results.

Safety Tip- 1

Don’t use a plasma cutter around flammable materials such as fuel lines, brake lines, gas tanks. A plasma cutting machine can easily melt through these materials. So, you should check the cutting area for spilled oil, old paint catching fire, and all other fire hazards before starting using a plasma cutter.


Safety Tip- 2

Make sure your auto workshop has a “type B” fire extinguisher for oil-, gas, and paint-fire hazards. They are good for any garage to have on hand in case of an emergency.

Conclusion

So, what is the best plasma cutter for auto bodywork?

I’ve carefully tested and selected these 5 models. These are all excellent choices for auto bodywork. They are adequately powerful and easy to use.

To refinish, restore or repair your auto bodies, frames, and other parts, these short-listed plasma cutters are the best for the jobs.

No matter which one you purchase, it’ll be an investment in your auto repair garage.

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