Speed and clean edges against cost and simplicity.
Verdict
A plasma cutter cuts steel quickly, follows curves, and leaves an edge close to ready to weld. An angle grinder with a cut-off wheel costs a tenth as much, cuts straight lines slowly, and cannot follow a curve. Buy the grinder for occasional cutting; buy the plasma cutter if you fabricate regularly.
| Hypertherm Powermax 30 | DeWalt DWE402 Angle Grinder | |
|---|---|---|
| Cut speed | Fast | Slow |
| Curves | Yes, follows any line | Straight cuts only |
| Edge quality | Clean, minimal cleanup | Rough, needs grinding |
| Thickness | Up to about 3/8 in cleanly | Limited by wheel diameter |
| Running cost | Consumable tips, air, power | Cut-off wheels |
| Purchase price | High | Low |
You cut metal often, you need curves or shapes, or you are producing parts rather than making the occasional repair. The time difference on a day of cutting is enormous, and so is the difference in how the edges look.
Check Hypertherm Powermax 30 on Amazon
You cut metal a few times a year. A grinder and a stack of cut-off wheels handles it for a hundred dollars, and it does a dozen other jobs the plasma cutter cannot. Most home shops never outgrow this.
Check DeWalt DWE402 Angle Grinder on Amazon
Usually yes, and it must supply clean dry air at the rated pressure and volume. Some units include a built-in compressor, which removes a significant hidden cost. Check before buying.
Yes, and stainless too, which is one of its advantages over oxy-fuel cutting. It cuts any electrically conductive metal.
Rarely, unless you are fabricating regularly. The purchase price plus consumables plus a suitable compressor adds up fast, and a grinder plus a bandsaw covers most hobby needs for far less.
Comparison based on published manufacturer specifications and the general consensus of owner reports. We have not tested these units side by side. Confirm current prices and specifications before buying. As an Amazon Associate we earn from qualifying purchases, at no extra cost to you.