The market offers a wide range of plasma torches. Although their general operating principle is the same, individual models differ significantly in performance parameters and — most importantly — in their intended applications.

In a previous article, we discussed the components and operating principles of plasma cutting systems, as well as the various types of consumables designed for different processes. Now, let’s take a closer look at the torches offered by Hypertherm, one of the world’s leading manufacturers.

Torch Construction

Although Hypertherm torches vary in design details, their overall structure is similar, as they operate on the same fundamental principle. Each torch consists of three main elements: the torch body, the torch handle (or housing), and the lead set.

Lead Set

The torch is connected to the plasma power source (e.g., Powermax 45 XP) by a bundle of leads.

  • The gas line supplies gas to the torch.

  • The voltage lead delivers current to the electrode.

  • The pilot arc lead returns current to the power source during initial arc ignition.

  • The consumable-sensor wire detects whether the consumables are properly installed.

Because the leads are flexible, they can be exposed to mechanical damage during operation — especially in handheld applications. For this reason, an additional protective sleeve is often recommended.

Torch Body

The body — sometimes called the torch head — is the heart of the torch. It connects all leads and includes the torch head assembly, which supplies gas to the consumables and holds them in place.

The head also includes a cap sensor, a safety feature that detects whether the consumables are installed correctly. This prevents improper ignition and extends consumable life.
Torch-body designs vary depending on the torch type and application, which is why consumables must always be selected to match the exact model.

Housing (Handle)

The housing protects the internal components of the torch and serves as the operator’s grip — or as the attachment point for a CNC table or robot. Depending on the application, housings can differ dramatically, as we explain below.

Torch Applications

Hypertherm torches fall into three main categories:

  1. Handheld torches

  2. Mechanized torches

  3. Robotic torches

Handheld cutting remains highly popular, and interest in CNC technology continues to grow. Robotic plasma cutting is still the least common in many regions.

Handheld Torches

The defining feature of a handheld torch is the trigger, which initiates gas flow and current, starting the plasma arc. For safety and usability, the trigger must be ergonomic, durable, and equipped with a safety lock to prevent accidental activation.

The handle’s ergonomics directly affect operator comfort, precision, and safety. A properly shaped handle reduces fatigue and improves visibility of the cut. The torch should not be overly bulky.

To maximize ergonomics, Duramax handheld torches are available in two configurations:

  • 75° torch for general cutting

  • 15° torch designed for gouging applications

Hypertherm also offers extended-length Duramax Hyamp torches for demanding tasks such as scrapping. They come in lengths of 0.6 m, 1.2 m, and 1.8 m, improving operator reach and safety.

Mechanized Torches

When the torch is mounted on a CNC machine, operator ergonomics are no longer relevant. As a result, mechanized torch housings are much simpler.

Mechanized torches do not have a trigger — arc initiation is controlled electronically via the CNC interface.

Instead, they feature a rack system that allows the machine to raise and lower the torch precisely.

Robotic Torches

Robotic torches are engineered specifically for robotic cutting applications. They are compact and include special mounting grooves, allowing the robot arm to grip the torch securely and consistently.

Hypertherm robotic torches come in three bend angles:

  • 180°

  • 90°

  • 45°

Each configuration is suited for a different task, such as internal cutting, bevel cutting, or gouging.

Summary

Choosing the right torch is essential. It must be properly matched not only to the job but also to the plasma system you are using.

That’s why we are always ready to help. Our specialists can recommend the ideal torch and consumables for your specific needs.

To conclude, we invite you to watch two short videos from our partner Hypertherm showcasing the durability of Duramax torches.