PLASMACUTFORGE CNC plasma tools & shop-floor guides

CNC plasma cutting reference

Plasma Cutter Settings Chart by Material and Thickness

Use this free CNC plasma cutter settings chart to compare practical starting amperage, cutting speed, air pressure, and torch standoff for mild steel, stainless steel, and aluminum. Select the material and measurement system, then use the thickness chart as a starting reference for your plasma table.

View the Plasma Cutter Settings Chart Open the Plasma Cutting Settings Calculator
Starting reference—not a machine-specific cut chart.

Confirm the consumable, amperage, pressure, airflow, and duty-cycle limits in your plasma cutter manual. Make one change at a time and record the settings that produce repeatable results on your machine.

Chart controls

Choose the measurement system and material

Amps, speed, pressure and standoff

Plasma Cutter Starting Settings by Material Thickness

Metric · mm

The chart compares general starting settings for common mild-steel, stainless-steel, and aluminum thicknesses. Use the listed amperage, cutting speed, air pressure, and torch standoff as a test starting point rather than a replacement for the official cut chart supplied with your machine.

Material reference

Mild steel

32 thicknesses

General air-plasma starting ranges for common mild-steel plate and sheet.

Thickness Amperage Air pressure Cut speed Cut standoff
1 mm20–30 A3.8–4.1 bar3,810–5,080 mm/min1.6 mm
1.5 mm20–30 A3.8–4.1 bar3,810–5,080 mm/min1.6 mm
2 mm30–40 A4–4.3 bar2,980–3,962 mm/min1.7 mm
2.5 mm30–40 A4.1–4.4 bar2,642–3,454 mm/min2.2 mm
3 mm40 A4.1–4.4 bar2,303–2,946 mm/min2.8 mm
4 mm40 A4.2–4.6 bar1,651–2,159 mm/min3.2 mm
5 mm40–50 A4.3–4.7 bar1,177–1,685 mm/min3.2 mm
6 mm60 A4.4–4.8 bar1,346–1,854 mm/min3.2 mm
7 mm60 A4.5–4.9 bar1,258–1,738 mm/min3.2 mm
8 mm60–80 A4.6–5 bar1,060–1,500 mm/min3.2 mm
9 mm60–80 A4.7–5.1 bar861–1,262 mm/min3.2 mm
10 mm60–80 A4.7–5.2 bar730–1,103 mm/min3.2–3.4 mm
11 mm80 A4.8–5.3 bar667–1,024 mm/min3.2–3.9 mm
12 mm80 A4.8–5.3 bar603–945 mm/min3.2–4.4 mm
13 mm80 A4.8–5.4 bar547–868 mm/min3.3–4.8 mm
14 mm80–100 A4.9–5.4 bar506–800 mm/min3.5–4.8 mm
15 mm80–100 A5–5.4 bar466–731 mm/min3.8–4.8 mm
16 mm80–100 A5–5.5 bar426–663 mm/min4–4.8 mm
17 mm80–100 A5.1–5.5 bar385–594 mm/min4.3–4.8 mm
18 mm80–100 A5.1–5.5 bar345–526 mm/min4.5–4.8 mm
19 mm80–100 A5.2–5.5 bar305–457 mm/min4.8 mm
20 mm100 A+5.2–5.6 bar289–433 mm/min4.8 mm
21 mm100 A+5.2–5.6 bar273–410 mm/min4.8 mm
22 mm100 A+5.3–5.7 bar257–386 mm/min4.8 mm
23 mm100 A+5.3–5.7 bar241–362 mm/min4.8 mm
24 mm100 A+5.3–5.8 bar225–338 mm/min4.8 mm
25 mm100 A+5.4–5.8 bar210–314 mm/min4.8 mm
26 mm100 A+5.4–5.9 bar197–295 mm/min4.8–5 mm
27 mm100 A+5.5–6 bar186–278 mm/min4.8–5.3 mm
28 mm100 A+5.5–6.1 bar174–262 mm/min4.8–5.7 mm
29 mm100 A+5.6–6.1 bar163–245 mm/min4.8–6 mm
30 mm100 A+5.7–6.2 bar152–229 mm/min4.8–6.3 mm

Material reference

Stainless steel

32 thicknesses

Conservative starting ranges for air-plasma cutting on stainless steel.

Thickness Amperage Air pressure Cut speed Cut standoff
1 mm20–30 A3.8–4.1 bar3,048–4,064 mm/min1.6 mm
1.5 mm20–30 A3.8–4.1 bar3,048–4,064 mm/min1.6 mm
2 mm40 A3.9–4.2 bar2,647–3,529 mm/min2 mm
2.5 mm40 A4–4.3 bar2,246–2,995 mm/min2.4 mm
3 mm40 A4.1–4.4 bar1,845–2,460 mm/min2.8 mm
4 mm60 A4.2–4.6 bar1,419–1,901 mm/min3.2 mm
5 mm60 A4.3–4.7 bar1,244–1,682 mm/min3.2 mm
6 mm60 A4.4–4.8 bar1,069–1,463 mm/min3.2 mm
7 mm60 A4.6–4.9 bar933–1,286 mm/min3.2 mm
8 mm80 A4.7–5 bar814–1,127 mm/min3.2 mm
9 mm80 A4.8–5.1 bar695–968 mm/min3.2 mm
10 mm80 A4.8–5.2 bar591–829 mm/min3.4 mm
11 mm80 A4.9–5.3 bar504–710 mm/min3.9 mm
12 mm80 A4.9–5.3 bar417–591 mm/min4.4 mm
13 mm80 A5–5.4 bar348–500 mm/min4.8 mm
14 mm100 A5–5.4 bar324–471 mm/min4.8 mm
15 mm100 A5–5.5 bar300–443 mm/min4.8 mm
16 mm100 A5.1–5.5 bar276–415 mm/min4.8 mm
17 mm100 A5.1–5.6 bar252–387 mm/min4.8 mm
18 mm100 A5.1–5.6 bar227–358 mm/min4.8 mm
19 mm100 A5.2–5.7 bar203–330 mm/min4.8 mm
20 mm100 A+5.2–5.7 bar191–310 mm/min4.8–5 mm
21 mm100 A+5.3–5.8 bar179–291 mm/min4.8–5.3 mm
22 mm100 A+5.3–5.8 bar167–271 mm/min4.8–5.5 mm
23 mm100 A+5.4–5.9 bar156–251 mm/min4.8–5.8 mm
24 mm100 A+5.4–6 bar144–231 mm/min4.8–6 mm
25 mm100 A+5.5–6 bar132–211 mm/min4.8–6.3 mm
26 mm100 A+5.6–6.1 bar124–197 mm/min5–6.3 mm
27 mm100 A+5.6–6.2 bar118–186 mm/min5.3–6.3 mm
28 mm100 A+5.7–6.2 bar113–174 mm/min5.7–6.3 mm
29 mm100 A+5.7–6.3 bar107–163 mm/min6–6.3 mm
30 mm100 A+5.8–6.3 bar102–152 mm/min6.3 mm

Material reference

Aluminum

32 thicknesses

Starting ranges for air-plasma cutting on common aluminum plate thicknesses.

Thickness Amperage Air pressure Cut speed Cut standoff
1 mm40 A4–4.4 bar4,572–6,096 mm/min1.6 mm
1.5 mm40 A4.1–4.5 bar4,399–5,865 mm/min1.6–1.9 mm
2 mm40 A4.1–4.5 bar4,226–5,634 mm/min1.6–2.3 mm
2.5 mm40 A4.2–4.6 bar4,052–5,403 mm/min1.6–2.7 mm
3 mm40 A4.2–4.7 bar3,879–5,172 mm/min1.6–3 mm
4 mm40–50 A4.4–4.8 bar3,175–4,318 mm/min2.4–3.2 mm
5 mm40–50 A4.5–4.8 bar2,472–3,421 mm/min3.2 mm
6 mm60 A4.6–4.9 bar2,134–2,743 mm/min3.2 mm
7 mm60 A4.7–5 bar1,810–2,318 mm/min3.2 mm
8 mm80 A4.8–5.1 bar1,492–2,000 mm/min3.2 mm
9 mm80 A4.8–5.2 bar1,175–1,683 mm/min3.2 mm
10 mm80 A4.8–5.3 bar937–1,405 mm/min3.4 mm
11 mm80 A4.9–5.3 bar778–1,167 mm/min3.9 mm
12 mm80 A4.9–5.3 bar619–929 mm/min4.4 mm
13 mm80 A5–5.4 bar496–745 mm/min4.8 mm
14 mm100 A5–5.4 bar456–689 mm/min4.8 mm
15 mm100 A5–5.5 bar415–632 mm/min4.8 mm
16 mm100 A5.1–5.5 bar375–576 mm/min4.8 mm
17 mm100 A5.1–5.6 bar335–519 mm/min4.8 mm
18 mm100 A5.1–5.6 bar294–463 mm/min4.8 mm
19 mm100 A5.2–5.7 bar254–406 mm/min4.8 mm
20 mm100 A+5.2–5.7 bar238–383 mm/min4.8–5 mm
21 mm100 A+5.3–5.8 bar222–359 mm/min4.8–5.3 mm
22 mm100 A+5.3–5.8 bar206–335 mm/min4.8–5.5 mm
23 mm100 A+5.4–5.9 bar190–311 mm/min4.8–5.8 mm
24 mm100 A+5.4–6 bar175–287 mm/min4.8–6 mm
25 mm100 A+5.5–6 bar159–264 mm/min4.8–6.3 mm
26 mm100 A+5.6–6.1 bar146–244 mm/min5–6.3 mm
27 mm100 A+5.6–6.2 bar135–227 mm/min5.3–6.3 mm
28 mm100 A+5.7–6.2 bar124–211 mm/min5.7–6.3 mm
29 mm100 A+5.7–6.3 bar113–194 mm/min6–6.3 mm
30 mm100 A+5.8–6.3 bar102–178 mm/min6.3 mm

Five important variables

What Controls CNC Plasma Cut Quality

01

Plasma cutter amperage

Match amperage to the installed consumables and material thickness. Too little power usually requires an excessively slow cut, while using amperage outside the consumable rating can damage the nozzle or electrode.

02

Plasma cutting speed

Cutting speed strongly affects dross, penetration, and bevel. Adjust speed in small steps only after confirming the torch, airflow, height, and consumables are correct.

03

Air pressure and airflow

Pressure must remain stable while cutting. Clean, dry air and adequate sustained airflow matter more than the compressor tank pressure alone.

04

Torch standoff and cut height

Hold the torch at the correct cutting height and use a higher pierce height when required. Incorrect standoff can increase bevel, damage consumables, and destabilize the arc.

05

Plasma cutter consumables

A damaged nozzle, worn swirl ring, or deeply pitted electrode can ruin a cut even when the numerical settings appear correct.

Shop-floor diagnosis

Read the Plasma Cut Before Changing Settings

Heavy removable bottom dross

This commonly indicates a cut that is too slow. Increase cutting speed gradually and retest before changing several other settings.

Top spatter or incomplete penetration

This can indicate excessive cutting speed, insufficient amperage, incorrect consumables, unstable air pressure, or insufficient airflow.

Excessive plasma-cut bevel

Check torch squareness, torch standoff, consumable condition, cut direction, machine motion, and arc stability before changing amperage.

Rough or wandering cut face

Inspect the nozzle and electrode, then verify clean dry air, stable flowing pressure, correct torch height, and smooth machine movement.

Plasma cutter air-system reference

Typical Plasma Cutter Air Demand by Amperage

A plasma cutter requires both adequate pressure and sustained airflow. Compressor tank pressure alone does not prove that the machine is receiving enough air while the torch is operating.

Amperage range Pressure (bar) Flow (L/min) Shop starting point
20–30 A3.8–4.599–1272–3 hp class
30–50 A4.1–4.8127–1703–5 hp class
50–70 A4.5–5.2170–2125 hp class
70–100 A4.8–5.9212–2835–7.5 hp class
100 A+5.5–6.6283–4257.5–10 hp class

Measure pressure at the plasma cutter while air is flowing. Always verify the required pressure and airflow in the manufacturer documentation for your exact plasma cutter, torch, and consumables.

Need help checking compressor capacity? Use the Plasma Cutter Air Compressor Sizing Guide .

Frequently asked questions

Plasma Cutter Settings Questions

What plasma cutter settings should I use?

Start with settings matched to the material, thickness, installed consumables, and available amperage. Confirm the ranges in the plasma cutter manual and make one controlled adjustment at a time.

How much air pressure does a plasma cutter need?

Required air pressure and airflow depend on the machine and amperage. Measure pressure while air is flowing and verify both pressure and sustained flow against the manufacturer documentation.

How does cutting speed affect plasma cut quality?

Cutting too slowly commonly produces heavy removable bottom dross. Cutting too quickly can cause incomplete penetration, top spatter, excessive lag lines, or a trailing arc.

Should amperage match the plasma cutter consumables?

Yes. The selected amperage must remain within the rating of the installed electrode and nozzle. Incorrect or mismatched consumables can reduce cut quality and consumable life.

Continue improving your machine-specific settings.

Use the Plasma Cut Quality Troubleshooter to diagnose dross, bevel, rough edges, arc-transfer problems, and consumable damage.

Learn how to validate and document repeatable values in the Machine-Specific Plasma Cut Chart Guide .