When Was the Plasma Cutter Invented? A Dated History (1957–2026)

When Was the Plasma Cutter Invented? The Short Answer

The plasma cutter was invented in 1957, when Robert Gage patented the plasma arc cutting process while working at Union Carbide. Wikipedia's plasma cutting entry and The Fabricator's history of the process both trace the technique back to that patent.

What is plasma cutting? Plasma cutting is a thermal process that cuts electrically conductive metal using a high-velocity jet of ionized gas. The electrically conductive gas melts the metal, and the force of the jet blows the molten material out of the cut.

The invention didn't come out of nowhere. It grew from 1940s and 1950s research into plasma torches and TIG (gas tungsten arc) welding, where engineers found that squeezing an arc through a small opening made it far hotter and more focused than an open arc (American Torch Tip covers this background).

Today, plasma cutting is used on steel, stainless steel and aluminum, and it's a core process in automotive, mining and construction fabrication. At BSG, a Kitchener, Ontario fabricator operating since 1987, our plasma cutting services are part of our wider fabrication work.

Plasma Cutting Timeline: From 1957 Patent to Modern CNC Systems

Plasma cutting has evolved from the 1957 patent to dual-gas, water-injection, air plasma, CNC and high-definition systems. Here's how that happened, decade by decade.

Before plasma: oxy-fuel cutting. Fabricators relied on flame cutting, also called oxy-fuel cutting. It works well on carbon steel, but it can't cut stainless steel or aluminum effectively because their oxides resist melting at flame temperatures. Plasma could cut those metals, and it was much faster on thin and mid-thickness plate.

1940s-1950s: the research. Work on constricted arcs and TIG welding led to the development of the plasma torch. Researchers learned that forcing an arc through a narrow nozzle concentrated its energy dramatically. Wikipedia summarizes this lineage.

1957: the patent. Robert Gage's plasma arc cutting patent at Union Carbide marked the start of the process as a cutting method.

1960s: early commercial adoption. Dual-gas torches, which add a separate shield gas, and water-injection torches improved cut quality, cutting speed and nozzle life. The early systems were costly and used mainly in industry. The Fabricator and this account of plasma cutting's unusual history describe how these refinements spread.

1970s-1980s: air plasma and automation. Air plasma cutting, which uses compressed air as the plasma gas, made the process cheaper and more accessible. It also led to portable units that smaller shops could afford. During this period, CNC tables began integrating plasma torches into automated production, so cuts could follow a programmed path instead of a steady hand.

1990s onward: high-definition plasma. Constricted arcs and refined consumables now deliver cuts approaching laser quality on many plate thicknesses. Hypertherm's overview of how plasma cutters work outlines this progression from early arc cutting to modern precision systems.

A separate timeline: laser cutting. Lasers emerged as their own technology with a different history, which you can read in our history of laser cutting. Plasma remains the favored choice for thicker conductive plate and for lower cost per cut, while laser cutting suits finer detail on thinner material. For a look at other options, see our laser vs. waterjet cutting comparison, and our guide to what industrial cutting machines can cut for context on modern capabilities.

Plasma cutting in fabrication today. Modern plasma tables handle automotive brackets, mining equipment components and structural steel plate for construction. Our CWB and AWS certifications and 44,000 sq ft facility mean a cut part can move straight into welding and structural steel work, or into automotive fabrication, under one roof. For more reading, browse our plasma cutting articles.

Plasma Cutter FAQs

Is a plasma cutter hotter than the sun?

Yes, compared with the sun's surface. A plasma cutter's arc can reach roughly 20,000-30,000°C in the arc core, while the sun's surface is about 5,500°C (Hypertherm). The sun's core is far hotter, around 15 million°C, and the plasma arc is only a narrow, localized column, so the comparison applies to the surface only.

Do plasma cutters actually make plasma?

Yes. An electric arc passes through a constricted nozzle and ionizes compressed gas (such as air, nitrogen or oxygen), turning it into electrically conductive plasma, as Wikipedia explains. That jet melts the metal and blows it clear of the cut. For a step-by-step look at the equipment, read how CNC plasma cutting machines work.

Do plasma cutters emit radiation?

Yes, they emit non-ionizing ultraviolet and infrared radiation, plus visible light, which can cause eye and skin burns. Operators should use appropriate shade-rated eye protection (per CSA/ANSI standards), flame-resistant clothing and covered skin, along with fume extraction or good ventilation. They don't emit ionizing radiation like X-rays.

Is plasma cutting as bright as welding?

Plasma cutting is very bright and needs proper eye protection, but it's generally somewhat less intense than high-amperage arc welding. Required lens shade depends on the cutting current, so follow the manufacturer's and CSA/ANSI Z87.1 and AWS shade recommendations, and never view the arc without a filter lens.

How does plasma cutting compare with laser cutting?

Plasma is usually the better value on thick conductive plate, while lasers win on precision and fine detail in thinner sheet. Our plasma vs. laser cutting comparison breaks down cost, speed and edge quality. Lasers also cut steel well, as covered in cutting steel with a laser, and our guide to laser cutting thickness limits shows where plasma takes over.

How is laser cutting different from plasma cutting?

A laser melts or vaporizes metal with a focused beam of light, while plasma uses an electric arc and ionized gas. Because plasma needs the metal to conduct electricity, it only works on conductive materials. Lasers don't have that requirement. We explain the mechanics in how laser cutting works.

If you have a project that needs plasma-cut parts, we're happy to talk through it. You can reach us through our plasma cutting page.