Hypertherm XPR300

$100,000 - $175,000 (power supply and gas console); $350,000 - $700,000 (complete system with table) Updated 2026-03-16

Key Specifications

output current

30–300 A

input voltage

380–600 V, 3-ph, 50/60 Hz

rated output power

300 A at 150 V (45 kW)

cut capacity mild steel production

50 mm (2 in)

cut capacity mild steel severance

80 mm (3-1/8 in)

cut capacity stainless production

38 mm (1-1/2 in)

Overview

The Hypertherm XPR300 is the company's current-generation flagship high-definition plasma cutting system, introduced in 2017 as the successor to the HyPerformance Plasma (HPR) series. With 300 amps of output and Hypertherm's X-Definition plasma technology, the XPR300 delivers a measurable step forward in cut quality over the HPR series — producing ISO 9013 Class 2 or better edge angularity on mild steel up to 50 mm and reducing dross formation across all material types. It represents the state of the art in mechanized plasma cutting quality as of 2026.

X-Definition technology centers on Hypertherm's Vented Water Injection (VWI) process for mild steel cutting. By injecting water into the shield gas stream in a precisely controlled pattern, the plasma arc is constricted beyond what is achievable with gas-only shielding. The result is a narrower kerf, reduced bevel angle (consistently under 3 degrees on mild steel to 25 mm), and a near-laser-quality edge finish on thinner materials. The XPR300 also incorporates Vent-to-Shield technology and a new electrode design that significantly extends consumable life — Hypertherm rates XPR consumables at two to four times the life of equivalent HPR consumables under the same operating conditions.

The XPR300 pairs with Hypertherm's Commandworks cutting management software and is compatible with leading CNC table controls from Burny, Hypertherm's own Phoenix, and third-party controls from Lincoln, ESAB, and others. The Auto-Gas system, inherited and refined from the HPR series, automatically controls up to six gas lines for multi-process cutting. The system handles mild steel (oxygen plasma), stainless (nitrogen or F5 gas mixes with water injection), and aluminum with a single torch, switching processes from the CNC control. A complete XPR300 installation on a new 5x10 or 8x20 foot table typically costs $350,000–$700,000.

In the competitive landscape, the XPR300 competes with ESAB's Precision Plasmarc systems, Lincoln Electric's Spirit II, and Kjellberg's HiFocus 360i. Independent cut quality comparisons consistently place the XPR300 at or near the top of the high-definition plasma class for edge quality on mild steel. Shops that have migrated from the HPR series report a significant reduction in secondary grinding and cleanup operations, which offsets a portion of the higher per-consumable cost of the XPR cartridge system.

Full Specifications

Parameter	Value
Output Current	30–300 A
Input Voltage	380–600 V, 3-ph, 50/60 Hz
Rated Output Power	300 A at 150 V (45 kW)
Cut Capacity Mild Steel Production	50 mm (2 in)
Cut Capacity Mild Steel Severance	80 mm (3-1/8 in)
Cut Capacity Stainless Production	38 mm (1-1/2 in)
Cut Capacity Aluminum Production	38 mm (1-1/2 in)
Cut Quality Mild Steel	ISO 9013 Class 2 (≤3° bevel) to 50 mm
X Definition Process	Vented Water Injection (VWI) for mild steel
Gas System	Auto-Gas, up to 6 gas lines
Consumable Life Vs Hpr	2–4x longer (cartridge system)
Compatible Controls	Hypertherm Phoenix, Burny, Lincoln, ESAB, third-party
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Strengths & Limitations

Strengths

X-Definition technology with Vented Water Injection delivers near-laser edge quality on mild steel to 50 mm — the best cut quality available in the plasma class
Consumable cartridge system lasts 2–4x longer than HPR-series consumables, reducing per-cut consumable cost despite a higher per-cartridge price
Auto-Gas system handles mild steel, stainless, and aluminum process switching automatically, enabling fast material changeovers without manual gas reconfiguration
ISO 9013 Class 2 edge quality (under 3 degrees bevel) reduces secondary grinding and cleanup operations significantly compared to conventional plasma

Limitations

Maximum 300A output means the XPR300 cannot match the HPR400XD's production cutting speed on material above 50 mm — very heavy plate operations may still require the higher-amperage system
High capital cost and gas infrastructure requirements (oxygen, nitrogen, water injection) limit deployment to volume cutting operations where quality savings offset investment
Consumable cartridge system, while longer-lived, is proprietary and more expensive per unit than HPR or conventional plasma consumables

Best For

High-volume structural, pressure vessel, and process equipment fabricators where cut quality directly affects downstream weld prep and reject rates Shops transitioning from conventional plasma to high-definition who need the best available cut quality without moving to laser cutting Multi-material operations cutting mild steel, stainless steel, and aluminum on the same table with automated process switching Operations where reduced secondary operations (grinding, deburring) are a cost driver and justify the premium over conventional or HPR-class plasma

Frequently Asked Questions

01 What is X-Definition plasma and how does it differ from high-definition plasma?

X-Definition is Hypertherm's branding for the XPR series' improved arc constriction technology, centered on Vented Water Injection (VWI) for mild steel. Standard high-definition plasma (like the HPR series) uses gas-only arc stabilization. VWI further constricts the arc column, reducing kerf width and bevel angle. On mild steel to 25 mm, XPR cut quality approaches laser quality in terms of edge angularity.

02 How does the XPR300 compare to laser cutting for edge quality?

On thin mild steel (under 6 mm), fiber laser cutting is faster and produces tighter tolerances than the XPR300. From 6 mm to 25 mm, XPR300 cut quality is competitive with lower-power fiber lasers in terms of edge finish, though laser maintains a kerf and tolerance advantage. Above 25 mm, the XPR300 is more competitive with high-power laser systems, and above 40 mm, plasma generally has a cost and speed advantage over equivalent-thickness laser cutting.

03 Does the XPR300 support bevel cutting?

Yes. The XPR300 is compatible with bevel cutting heads from Hypertherm-certified table manufacturers. Bevel angles up to ±45 degrees are supported for weld prep. The improved arc quality of the XPR300 produces more consistent bevel face quality compared to HPR-series bevel cutting, reducing post-bevel grinding.

04 What is the consumable cost comparison between XPR300 and HPR400XD?

XPR300 cartridge consumables cost more per unit than HPR electrodes and nozzles, but last 2–4x longer. Hypertherm's cost-per-cut analysis typically shows the XPR300 at a lower total consumable cost per linear meter of cut. The larger savings come from reduced scrap and secondary operations enabled by the better edge quality.

05 What power supply and gas infrastructure is required for the XPR300?

The XPR300 requires three-phase 380–600V input power (typical load 45 kW at full output). Gas requirements include oxygen (plasma gas for mild steel), nitrogen (plasma gas and shield for stainless and aluminum), compressed air (shield gas), and a water supply or water injection module for VWI on mild steel. Argon-hydrogen is optional for specialty stainless processes.