Hypertherm HPR400XD

$80,000 - $150,000 (power supply/gas console); $250,000 - $600,000 (complete system with table) Updated 2026-03-16

Key Specifications

output current

30–400 A

input voltage

380–600 V, 3-ph, 50/60 Hz

rated output power

400 A at 160 V (64 kW)

cut capacity mild steel

80 mm (3-1/8 in) severance; 50 mm production

cut capacity stainless

50 mm (2 in) production

cut capacity aluminum

50 mm (2 in) production

Overview

The Hypertherm HPR400XD is a 400-amp high-definition plasma cutting system engineered for heavy industrial cutting of thick plate — specifically structural fabricators, shipbuilders, pressure vessel manufacturers, and heavy equipment OEMs who need to cut carbon steel up to 80 mm (3-1/8 inches) at production speeds. The HPR400XD represents the upper tier of Hypertherm's HyPerformance Plasma (HPR) series, a family that preceded the XPR300 and remains in wide deployment across large gantry and bevel cutting systems globally.

High-definition plasma distinguishes itself from conventional plasma through a vortex-stabilized plasma arc with tighter gas management, producing a narrower, more columnar arc column. The HPR400XD uses Hypertherm's Auto-Gas system — a computer-controlled gas console that manages up to seven gas lines (plasma gas, shield gas, water injection for stainless) and selects the correct gas mix automatically based on the selected cut process. This eliminates manual gas selection and allows the machine to switch between cutting mild steel with oxygen plasma, stainless with nitrogen/water, and aluminum with nitrogen without operator intervention.

In production environments, the HPR400XD is typically mounted on large-format bridge-type gantry tables (8x20 feet to 12x60 feet) or beam-line plasma systems. Its 400A output gives it the arc force to cut 80 mm carbon steel at 150–250 mm/min, and the high-definition optics produce ISO 9013 Class 2 or better edge quality on mild steel up to 38 mm. Above 38 mm, edge quality degrades toward class 3–4, but dimensional accuracy and cut-through reliability remain strong to the full 80 mm capacity. Bevel cutting heads for the HPR400XD support bevel angles up to ±45 degrees for weld prep on heavy plate.

The HPR400XD requires three-phase 380–600V input power and a significant gas infrastructure investment (oxygen, nitrogen, compressed air, and optionally argon-hydrogen for stainless). Total installed cost including table, gas console, and bevel head typically runs $250,000–$600,000 depending on table size and configuration. The system competes with Lincoln Electric's Spirit II, ESAB's m3 Plasma on high-amperage tables, and Kjellberg's HiFocus systems in the heavy plate market.

Full Specifications

Parameter	Value
Output Current	30–400 A
Input Voltage	380–600 V, 3-ph, 50/60 Hz
Rated Output Power	400 A at 160 V (64 kW)
Cut Capacity Mild Steel	80 mm (3-1/8 in) severance; 50 mm production
Cut Capacity Stainless	50 mm (2 in) production
Cut Capacity Aluminum	50 mm (2 in) production
Cut Quality Mild Steel To 38mm	ISO 9013 Class 2
Gas System	Auto-Gas computer-controlled console (up to 7 gas lines)
Plasma Gases	O2 (mild steel), N2, F5 (stainless, aluminum)
Shield Gases	Air, N2, H2O (water injection for stainless)
Bevel Cutting	Up to ±45 degrees (with optional bevel head)
Torch Body	HPR torch with interchangeable cartridge consumables

Strengths & Limitations

Strengths

400A output covers the full range of heavy plate cutting from 6 mm to 80 mm, eliminating the need for a separate oxy-fuel system for most plate work
Auto-Gas computer-controlled console automatically selects gas mixes for mild steel, stainless, and aluminum — reducing setup errors and enabling fast material changeovers
High-definition arc quality (ISO 9013 Class 2) on mild steel to 38 mm produces cleaner edges than conventional plasma, reducing secondary operations
Bevel cutting capability up to ±45 degrees enables single-setup weld prep on heavy plate, eliminating secondary beveling operations

Limitations

Substantial infrastructure requirement: three-phase power, oxygen, nitrogen, compressed air, and water supply are all necessary for full multi-process capability
High capital cost and complexity compared to conventional plasma systems — justified only for shops with significant heavy plate volume
The HPR series has been superseded by the XPR300 for new installations in the mid-range; the HPR400XD remains the option for shops needing 400A, but the XPR platform offers better cut quality per amp

Best For

Structural steel fabricators, shipyards, and heavy equipment manufacturers cutting carbon steel plate from 25 mm to 80 mm at high volume Operations requiring multi-material capability (mild steel, stainless, aluminum) with automatic gas changeover between jobs Shops investing in bevel cutting for weld prep automation on heavy plate, replacing manual beveling or oxy-fuel bevel operations Large-format gantry table installations (8x20 feet and larger) where a single high-power plasma system serves multiple cutting zones

Frequently Asked Questions

01 How does the HPR400XD differ from the Hypertherm XPR300?

The HPR400XD provides 400 amps and is optimized for heavy plate cutting above 38 mm, while the XPR300 delivers 300 amps with a newer X-Definition arc technology that produces significantly better cut quality and edge angularity on mild steel up to 50 mm. For most mid-range applications (6–50 mm), the XPR300 offers better cut quality. The HPR400XD retains an advantage in raw cutting power for material above 50 mm.

02 What gases does the HPR400XD require?

Full capability requires oxygen (plasma gas for mild steel), nitrogen (plasma gas for stainless and aluminum, shield gas), compressed air (shield gas), and optionally water injection or argon-hydrogen for specialty stainless processes. The Auto-Gas console manages all lines automatically. Shops cutting only mild steel can operate with oxygen and air only.

03 Can the HPR400XD be used for bevel cutting?

Yes. Hypertherm and compatible table manufacturers offer bevel cutting heads that accept HPR torch bodies. The system supports bevel angles up to ±45 degrees for V-groove, Y-groove, and K-groove weld prep profiles. Bevel accuracy depends on the motion system and torch height control on the table.

04 What table size is typical for an HPR400XD installation?

The HPR400XD is most commonly mounted on large-format gantry tables — 8x20 feet to 14x60 feet — serving structural plate operations. It is also used on beam-line and pipe/tube cutting systems. For smaller 4x8 or 5x10 foot tables, the HPR400XD is oversized; a Powermax125 or XPR300 at lower amperage is more appropriate.

05 Is the HPR400XD still available new?

The HPR series has transitioned to end-of-life for new production in most markets, with the XPR300 being Hypertherm's current high-definition flagship. However, Hypertherm continues to support the HPR400XD with full consumable and parts availability. Used HPR400XD systems are plentiful on the secondary market from $30,000 to $80,000 depending on condition.