Estimate your monthly and annual shield gas or compressed air costs based on your plasma cutter type and cutting volume.
Actual torch-on time, not total shop hours. Hobby: 2-5 hrs/wk, Small shop: 10-20 hrs/wk, Production: 30-50 hrs/wk.
Estimates are based on typical industry flow rates and average US pricing for industrial gases. Actual costs vary by region, supplier, delivery method, and contract terms. Compressed air costs reflect electricity to run the compressor only.
Select your gas type, amperage class, and cutting hours, then click Calculate to see your estimated costs.
The gas you use affects cut quality, edge finish, consumable life, and operating cost. Here is when and why to use each type.
The most common and cost-effective option for CNC plasma cutting. Compressed air works well on mild steel, aluminum, and stainless steel up to about 1" thick. It produces a slightly oxidized edge on stainless but is perfectly acceptable for most fabrication work.
Nitrogen produces cleaner, oxide-free edges on stainless steel and aluminum compared to compressed air. It is the standard choice when edge quality matters and post-processing needs to be minimized. Nitrogen also extends consumable life because it runs cooler than oxygen-based gases.
Oxygen is the premium choice for mild steel cutting. The exothermic reaction between oxygen and carbon steel increases cut speed by 20-25% and produces the smoothest, most square edge of any plasma gas on mild steel. However, oxygen should never be used on stainless or aluminum as it causes heavy oxidation.
H35 is a specialty mix of 65% argon and 35% hydrogen, used exclusively on stainless steel and aluminum when the highest edge quality is required. It produces a mirror-smooth, shiny edge with virtually no dross. H35 is the most expensive plasma gas but eliminates the need for post-cut grinding on visible edges.
| Material | Best Gas | Budget Alternative | Edge Quality |
|---|---|---|---|
| Mild Steel (general) | Compressed Air | -- | Good |
| Mild Steel (premium edge) | Oxygen (O2) | Compressed Air | Excellent |
| Stainless Steel | H35 or Nitrogen | Compressed Air | Good to Excellent |
| Aluminum | Nitrogen (N2) | Compressed Air | Good |
| Stainless (visible / decorative) | H35 | Nitrogen | Mirror finish |
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