Kjellberg HiFocus 160neo

The Kjellberg HiFocus 160neo represents the pinnacle of Kjellberg's fine-plasma CNC cutting technology. Built around the company's fourth-generation HiFocus plasma process, the 160neo delivers 160 amperes through a precision-engineered torch and nozzle system that produces cut quality widely regarded as the best achievable by plasma — competitive with fiber laser on mild steel up to approximately 20 mm and superior to conventional high-definition plasma at thicknesses above 25 mm. For fabricators who need laser-grade cut quality but process material too thick or too varied for economical laser cutting, the HiFocus 160neo is the benchmark product.

Kjellberg's HiFocus technology distinguishes itself through a combination of patented arc-focusing techniques: contoured nozzle geometry that narrows the plasma jet diameter, optimized gas swirl that maintains arc stability at high energy density, and electromagnetic focusing that stabilizes the plasma column against turbulence-induced wander. The cumulative effect is a plasma arc that maintains a near-cylindrical cross-section throughout the material thickness rather than the inverted-cone shape typical of conventional plasma. This produces cuts with angularity values in ISO 9013 quality range 2–3 on mild steel, near-zero bevel on plate up to 12 mm, and smooth, post-weld-ready surfaces on structural sections.

The neo suffix in the HiFocus 160neo denotes a generational update to the original HiFocus 160 that introduced digital power source control, modernized THC communication protocols, and an updated torch body with improved coolant channels for enhanced electrode and nozzle thermal management. The digital controller allows real-time adaptive arc-voltage compensation — the system continuously adjusts arc length to compensate for plate warpage and surface irregularities, which is critical for maintaining consistent cut quality on large structural plates that may not be perfectly flat. This adaptive capability significantly reduces the operator interventions and parameter adjustments that would otherwise be required on warped or scaled plate.

At 160 A, the HiFocus 160neo handles mild steel up to approximately 50 mm in production mode, stainless to 40 mm, and aluminum to 35 mm. For precision applications (parts requiring minimal secondary operations), Kjellberg recommends up to 30 mm on mild steel and 20–25 mm on stainless and aluminum. The system supports Kjellberg's full gas matrix including oxygen, nitrogen, argon-hydrogen, and water injection, providing the flexibility to optimize the plasma process independently for each material type rather than compromising with a single gas setup.

The HiFocus 160neo's position in Kjellberg's lineup — above the SmartFocus 100 and i-cut 200 in cut quality, below the i-cut 300 in maximum thickness — makes it the choice for precision plate fabricators who need both quality and capacity. Aerospace sub-suppliers, precision engineering firms, and high-end structural fabricators in Europe and export markets frequently specify the HiFocus 160neo when plasma is the chosen process. The system integrates with Kjellberg's plasma management software for production monitoring, consumable life tracking, and cut-quality documentation, which is increasingly demanded in ISO-certified manufacturing environments.