Plasma Cutter vs Angle Grinder: Which One Should You Buy?

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Below: what each tool does, when the plasma cutter wins, when the angle grinder wins, what size plasma cutter the listings support, and how a plasma cutter works.

Plasma cutter vs angle grinder: what each one does

A plasma cutter blows a constricted arc through conductive metal and blasts the molten metal out of the kerf with compressed air. It cuts sheet and plate in any shape you can trace, on steel, stainless steel, aluminum and copper per the bestarc listing. An angle grinder spins a disc: a cutoff wheel slices, a grinding wheel smooths, a wire wheel strips. The plasma cutter is a cutting-only machine that needs an air compressor; the grinder is a hand tool that switches jobs with the disc. All four listings in this guide are plasma cutters, so the angle grinder side below is the general tool, and every figure belongs to a named listing.

When the plasma cutter wins

• Freehand shapes in plate. Curves, brackets, gussets and bolt circles are plasma work. The SILATU states mesh and expanded metal cutting, and the bestarc states grid cutting with an adjustable pilot arc.
• Fast cuts in sheet and plate. The 50A units here state a 1/2 in clean cut: the bestarc, the SILATU and the YESWELDER all state it at 220V. The PRIMEWELD is the 60A step up with a stated 60% duty cycle at 60 amps.
• Rusty, painted or coated metal. The bestarc states a non-touch pilot arc that cuts through rusted, painted or coated metal with no surface prep, plus a dedicated rust removal mode. The SILATU states the same non-touch pilot arc.
• Long straight cuts. The 4T mode stated on the bestarc, SILATU and YESWELDER lets you release the trigger during long cuts instead of holding it.

See our best plasma cutter for home use for four picks sized for garages.

When the angle grinder wins

• Grinding and weld cleanup. The plasma cutter only cuts; smoothing beads, beveling edges and dressing the heat affected zone are grinder work.
• Cutting small stock. Bar, tube and threaded rod cut faster with a cutoff wheel than with a plasma torch setup, with no compressor to hook up.
• No air, no power draw. The grinder plugs in and goes. Every plasma cutter here needs an air compressor: the bestarc states a 50 to 80 PSI range, the YESWELDER 45 to 75 PSI, and the SILATU a stated 250 liters per minute flow.
• One tool, many jobs. Cutting, grinding, stripping and polishing with a disc change beats a single-purpose cutter for a small shop.

What size plasma cutter do I need

Match the clean cut figure to your thickest common plate. Three 50A units here state a 1/2 in clean cut at 220V: the bestarc, the SILATU and the YESWELDER. The SILATU states 60% duty cycle, and the PRIMEWELD states 60% duty cycle at 60 amps as the heavier option. The bestarc states a recommended 1/2 in at 35A on 110V and 2/3 in at 50A on 220V, so 110V power costs you thickness. If your work is mostly 1/4 in and under, the 50A class covers it; if you cut 1/2 in plate all day, the 60A unit with its stated duty cycle is the listing-backed step up.

How does a plasma cutter work, and what does it need

The machine ionizes compressed air into a plasma jet that melts the metal, and the air stream blows the molten metal out of the cut. That means two things the listings state plainly: an air compressor is required and not included, and the air must be clean and dry. The bestarc includes a built-in metal air filter with a 1/4 in quick-connect fitting, and the YESWELDER states a built-in rear air filter. The bestarc states 50 to 80 PSI and the YESWELDER states 45 to 75 PSI; the SILATU states a 250 liters per minute flow with no PSI figure. On power, the bestarc states recommended breakers of 40A at 110V and 30A at 220V. App control is a stated extra on the bestarc, with Bluetooth control up to 98 ft, and the PRIMEWELD states a PT60 torch with a euro central connection.

Frequently Asked Questions

What size plasma cutter do I need?

The 50A units here state a 1/2 in clean cut at 220V, which covers most garage plate work. The PRIMEWELD states 60A with a 60% duty cycle at 60 amps for heavier use. Buy for the clean cut figure, not the max cut figure.

How do I use a plasma cutter?

Connect dry compressed air within the listing’s stated PSI range, clamp the ground to the work, set the current for the thickness, and drag or standoff the torch along the line. The 2T mode needs continuous trigger pressure; 4T lets you release the trigger during long cuts, per the bestarc, SILATU and YESWELDER listings.

Can a plasma cutter cut aluminum?

The bestarc states it cuts steel, stainless steel, aluminum, copper and other conductive metals. The YESWELDER states the same metal list for its CUT-50DS PRO.

How do I cut with a plasma cutter on rusty metal?

The bestarc and SILATU state a non-touch pilot arc that starts without touching the metal, so rusted, painted or coated surfaces cut without prep. The bestarc also states a dedicated rust removal mode for cleaning the surface first.

Which of these states a warranty?

The PRIMEWELD states a 3 year warranty, the YESWELDER states 2 years, and the SILATU states a 1-year warranty. The bestarc states no warranty term.

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