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Don't settle for almost perfect. Here are some practical steps from James Flatman (AKA @notion_fabrication) to help you cut perfect circles using a manual plasma cutting machine.
Equipment used in video: Thermal Dynamics Cutmaster 60i
What is grate cutting mode on a plasma cutter?
Grate cutting mode is a specialised plasma cutting setting designed for expanded metal, grating, mesh, and other materials containing open gaps. It maintains a pilot arc when the torch passes between metal strands and automatically transfers the cutting arc when it reaches the next conductive surface. This allows continuous cutting without repeatedly releasing and pressing the torch trigger, improving cut consistency and reducing consumable wear.
Can you cut expanded metal and steel grating with a plasma cutter?
Yes. Plasma cutters can cut expanded metal, steel grating, perforated sheet, and other electrically conductive grid materials. However, the gaps between strands can cause repeated arc interruptions on machines without a dedicated grate cutting mode. Using a plasma cutter with automatic pilot arc control, such as the ESAB Cutmaster+ range, helps maintain consistent cutting performance across open sections.
What is the difference between normal cutting mode and grate cutting mode?
Normal plasma cutting mode is designed for continuous metal surfaces, such as solid steel plate or aluminium sheet. Grate cutting mode is intended for materials with gaps or openings that repeatedly interrupt the transferred cutting arc. It maintains the pilot arc between strands, allowing the torch to resume cutting automatically when it encounters metal. Normal mode is recommended for solid plate, while grate mode is better suited to expanded metal and grating.
How does grate cutting mode extend plasma consumable life?
Grate cutting mode reduces the number of full arc restarts required when cutting material with open gaps. Instead of extinguishing the arc completely between strands, the plasma cutter maintains a pilot arc that can quickly transfer back to the workpiece. This reduces repeated starting stress on the electrode and nozzle, helping extend consumable life and minimise downtime during expanded metal cutting.
Which ESAB Cutmaster plasma cutters support grate cutting mode?
The ESAB Cutmaster 30+, Cutmaster 50+, and Cutmaster 70+ all support grate cutting mode with automatic pilot arc control. The Cutmaster 30+ is suitable for lighter expanded metal and mesh applications, while the 50+ provides greater cutting capacity for heavier grating. The Cutmaster 70+ offers higher output for industrial flooring, heavy bar grating, and high-volume expanded metal cutting applications.