Automated Cutting Ultrasharp
Key Specifications
Accuracy
Repeatability
table sizes
plasma supply
minimum feature size
material range
Overview
The Automated Cutting Ultrasharp is a precision CNC plasma cutting system engineered specifically for fine-feature profile cutting applications where conventional plasma's kerf width and edge angularity are insufficient. The Ultrasharp system addresses a specific market segment — shops cutting intricate decorative metalwork, precision brackets, gaskets, and mechanical components from mild steel, stainless, and aluminum sheet where plasma is preferred over laser due to material thickness range or capital cost constraints.
The Ultrasharp uses a high-frequency stabilized plasma arc in combination with precision torch height control and a motion control system tuned for slow-speed accuracy rather than high-speed throughput. The result is a plasma system capable of cutting features and radii down to approximately 3 mm on thin sheet material (1–6 mm), which approaches the feature resolution of lower-power laser systems at a fraction of the capital cost. The system is not competitive with fiber laser for volume production of thin sheet, but for shops cutting 3–16 mm material with mixed feature sizes — including both large profile cuts and fine interior details — the Ultrasharp occupies a useful middle ground.
Automated Cutting offers the Ultrasharp on table sizes from 4x4 feet to 5x10 feet, targeting job shops and specialty fabricators rather than volume structural plate processors. The system integrates a 50–100A plasma power supply (customer's choice of Hypertherm Powermax or ESAB equivalent) with Automated Cutting's proprietary motion controller, which incorporates feed rate override and arc voltage compensation algorithms optimized for fine feature cutting. The torch height control system updates arc voltage feedback at a faster rate than conventional plasma THC systems, which reduces dip and dive on tight inside corners.
Pricing for the Ultrasharp system typically runs $35,000–$75,000 for a complete 4x8 or 5x10 foot installation including power supply. This positions it above entry-level plasma tables but well below high-definition industrial systems or entry-level fiber lasers. The target customer is a job shop or specialty fabricator that does decorative ironwork, architectural metalwork, custom brackets, or prototype parts in small-to-medium runs.
Full Specifications
| Parameter | Value |
|---|---|
| Table Sizes | 4x4 ft to 5x10 ft |
| Plasma Supply | 50–100A (Hypertherm Powermax or ESAB, customer choice) |
| Minimum Feature Size | ~3 mm radius on 1–6 mm material |
| Material Range | Mild steel, stainless steel, aluminum (1–16 mm typical) |
| Torch Height Control | High-speed arc voltage THC (proprietary) |
| Motion Control | Proprietary fine-feature optimized controller |
| Feed Rate Override | Dynamic, arc-voltage-based on inside corners |
| Drive System | Precision ballscrew or rack-and-pinion (table size dependent) |
| Cnc Control | Automated Cutting proprietary (DXF/DWG import) |
| Software | SheetCAM or compatible nesting CAM |
| Positioning Accuracy | ±0.15 mm |
| Repeatability | ±0.10 mm |
Strengths & Limitations
Strengths
- Fine-feature cutting capability approaching 3 mm minimum radius on thin sheet — significantly better than conventional plasma and competitive with entry laser for the same material range
- High-speed torch height control with dynamic feed rate override on inside corners reduces dip, dive, and arc extinguishment on complex profile geometry
- Capital cost of $35,000–$75,000 is a fraction of entry fiber laser pricing while covering a similar material thickness range for shops where feature resolution, not speed, is the primary requirement
- Plasma-supply-agnostic design allows use of widely available Hypertherm or ESAB consumable ecosystems for low operating cost and broad parts availability
Limitations
- Cutting speed is significantly slower than conventional plasma or high-definition plasma for large profile work — the Ultrasharp is optimized for accuracy, not throughput
- Maximum 16 mm practical material thickness is a limitation for shops that also need to cut structural plate — a separate higher-amperage system would be required
- As a specialty niche system, Automated Cutting's service and parts network is considerably smaller than Hypertherm's, Lincoln Electric's, or ESAB's — buyer should confirm service coverage in their region
Best For
Frequently Asked Questions
01
The Ultrasharp combines a high-update-rate arc voltage torch height control (which tracks surface variations faster than conventional THC), dynamic feed rate reduction on inside corners to prevent arc extinguishment, and a motion controller tuned for low-speed accuracy rather than high-speed throughput. Together these allow the system to navigate tight geometry that conventional plasma tables would either stall on or produce unacceptable edge quality.
02
On 1–3 mm mild steel, the Ultrasharp can cut interior radii down to approximately 3 mm with acceptable edge quality. On thicker material (6–10 mm), minimum practical radius increases to approximately 5–8 mm due to kerf width. These figures are approximate and depend on plasma power supply, consumable condition, and material quality.
03
For some applications, yes — particularly on material 3 mm and above where fiber laser speed advantages diminish and the XY feature resolution requirements are in the 3–10 mm range. Fiber laser cuts faster, produces a narrower kerf, and has better edge angularity on thin sheet. The Ultrasharp is a cost-effective alternative when production volume does not justify laser capital cost and feature resolution requirements are met by the plasma system's capability.
04
The Ultrasharp is offered with either a Hypertherm Powermax45 or Powermax65 (for 50A class) or a Powermax85 or Powermax105 (for applications up to 100A). ESAB equivalents are also supported. The customer selects the plasma supply based on their typical material range. The Ultrasharp control system integrates with all supported power supplies through a standard machine interface.
05
The Ultrasharp accepts NC code from SheetCAM, which is the recommended CAM package for its control. Standard DXF and DWG geometry files can be imported directly into SheetCAM for toolpath generation. Other CAM packages that output standard plasma G-code are also compatible. Automated Cutting provides post-processors for the most common nesting and CAM software packages.
Videos
Lincoln Electric
Kerf Developments
LCX SMT
MTDCNC
CPO Outlets
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