• • Each cutting process serves different industrial applications
  • Specific project requirements determine the best cutting method
  • Fiber laser cutting is ideal for quick and precise cuts of thin materials
  • Plasma cutting is best for cutting thick materials in budget-friendly ways
  • Waterjet cutting is better for versatility, material flexibility, and high-precision
  • Midland’s experts can help determine and deliver the best solution for your specific needs

When it comes to industrial fabrication, key factors include precision, efficiency, and selecting the appropriate manufacturing process from the start. It’s important to understand how the different cutting technologies work to make more informed decisions before fabrication begins. Even though many technologies can cut and shape materials, not all methods will deliver the same results when it comes to accuracy, speed, material type, production volume, and cost. 

In this guide, we compare three of the most widely used industrial cutting techniques: fiber laser cutting, plasma cutting, and waterjet cutting. We outline how each technique works, when to use each technique, pros and cons of each, and how to determine which option is the best fit for your project.

Each cutting technique is designed to solve specific challenges for industrial fabrication. Figuring out which solution works best for your application depends on cost, precision, material type, and finishing requirements. 

Below is a breakdown of how each of these cutting methods work and where it is commonly used.

Controlled by CNC systems, fiber laser cutting is a machining process that uses a focused laser beam to melt and vaporize material. The highly focused beam makes cutting extremely precise with little material waste and exceptional edges.

Known for its speed and accuracy, fiber laser cutting is the ideal choice for high-volume environments that require tight tolerances. Fiber laser is commonly used for components that require clean edges, consistency, and intricate shapes.

Key Elements of Fiber Laser Cutting

• • Great accuracy and repeatability
  • Quick cutting speeds for thin to thick materials
  • Clean edges require little to no secondary finishing
  • Ideal for materials like aluminum, stainless steel, carbon steel, copper, and brass
  • Works well for large-scale, automated production

Midland’s Advantage

Midland Industrial houses the AMADA ENSIS 3015 RI 9k Fiber Laser, which is one of the largest, high-power industrial lasers. Midland has one out of the few available in the region, making our shop a one-stop-shop for both plate and structural tube/channel cutting.

• • Additional rotary head provides versatility to process C-channel, angle iron, rectangle, and square tubing
  • Automatic adjustment for optimal processing of both thin and thick materials

Plasma cutting works by using a stream of gas that becomes superheated, creating plasma, to cut through materials that conduct electricity. The plasma melts the metals, and the air pressure blows the molten material away in order to leave a clean cut. 

Due to its high-temperature arc, plasma cutting is especially effective for cutting through thicker materials. Even though plasma cutting may be less precise than laser cutting, it can work with thick conductive materials while remaining cost-efficient.

Key Elements of Plasma Cutting

• • Well-suited for cutting anything from thin sheets to thick plates
  • Lower operating costs compared to laser systems
  • Faster cutting speeds for thicker materials
  • Ideal choice when speed and low costs are priorities 
  • Industry standard for heavy fabrication and structural work

Waterjet cutting is a machining technique that uses a high-pressure stream of water to cut through the material. For harder materials, such as steel, the water is mixed with an abrasive substance to increase the cutting power. 

Waterjet cutting is a cold process, which means there will be no warping or heat-affected zones. This makes waterjet ideal when using materials that could harden or distort under heat.

Key Elements of Waterjet Cutting

• • Cold process with zero heat distortion
  • Slower than other techniques but has high precision
  • Ability to cut a range of materials including plastics, composites, stone, and steel
  • High cutting edge quality with smooth finishes
  • Uses no hazardous materials and creates minimal waste

All three cutting techniques are widely used in industrial fabrication, but choosing which solution best aligns with your specific manufacturing goals depends on several factors. 

Fiber Laser Cutting: Pros and Cons

Cons

• • Primarily for metals only
  • Not as effective for extremely thick materials
  • Reflective risk (sensitive to materials like brass or copper)

Plasma Cutting: Pros and Cons

Cons

• • Not as precise as laser cutting
  • Larger heat-affected zone
  • May require additional finishing
  • Not suitable for intricate or tight-tolerance parts

Waterjet Cutting: Pros and Cons

Cons

• • Slower cutting speeds
  • Less efficient for high-volume metal production
  • Higher operating costs due to abrasives

Choose fiber laser cutting when:

• • Working with tight tolerances and precision requirements
  • Clean edges are needed with minimal finishing
  • Production speed and repeatability matter
  • Working with sheet metal or medium-thickness metals
  • High-volume manufacturing efficiency is a priority

Choose Plasma cutting when:

• • Cutting thick steel or heavy plate materials
  • Structural or industrial components are required
  • Budget efficiency is important
  • Ultra-fine precision is not necessary
  • Production speed is more important than edge quality

Choose waterjet cutting when:

• • Materials are heat-sensitive
  • Non-metal materials must be cut
  • Material properties must be maintained
  • Cold cutting precision is needed for complex shapes
  • Specialty or mixed-material projects are involved

Different industries rely on specific cutting technologies depending on performance requirements, regulatory standards, and production demands. Below, we’ve outlined which industries each cutting method commonly serves.

industries relying on fiber laser cutting

• • Electronics: great for micro-component fabrication, engraving and marking, and leaving minimal waste for PCBs and circuit components
  • Medical Device Manufacturing: makes small, intricate, and complex components with tight tolerances such as stents and surgical instruments
  • Automotive & EV: for cutting sheet metals such as body panels, exterior parts such as chassis components and exhaust systems, and interior materials like airbags
  • Aerospace: large-scale lasers like Midland’s use a rotary head for high-precision tube and channel components that meet strict weight and fitment standards

industries relying on plasma cutting

• • Construction & Mining: cuts heavy-duty base plates, structural beams, and equipment components where durability and raw material thickness are essential
  • Shipbuilding: ability to quickly cut thick, conductive metals such as steel, aluminum, and stainless steel, and capable of shaping hulls and bulkheads
  • Energy & Infrastructure: more sustainable option for structural steel components, heavy plate fabrication, and pipe and support structures

industries relying on waterjet cutting

• • Food processing: uses a sterile cutting stream to cut, portion, and trim food-grade products while minimizing downtime and eliminating cross-contamination
  • Architecture & Design: complex fabrication using cold-cutting to create custom facades, flooring, countertops, detailed mosaics, signage, and structural components
  • Aerospace & Defense: cuts thick composites or titanium components where maintaining the molecular properties of materials is critical

At Midland, we understand that successful industrial application outcomes come from choosing the right technology based on your specific engineering requirements and long-term performance goals. Midland approaches fabrication as a fully integrated process which begins with evaluating each application to determine the most efficient and reliable cutting solution. 

Our advanced equipment, which includes high-performance fiber laser systems and precision waterjet capabilities, gives us the power to support projects ranging from high-volume production components to custom fabrication needs. Midland’s experienced team of engineering experts can deliver a custom solution tailored to your exact needs through creative problem solving, long-term reliability, and quality craftsmanship.

midland’s cutting advantage

Partnering with Midland Industrial means you gain access to one of the largest fiber lasers in the country: Amada ENSIS 3015 RI 9K Fiber Laser. Our Amada ENSIS isn’t just a large machine, but a solution for high-precision processing of both flat sheets and complex shaped materials like angle iron and square tubing. Our specialized laser means Midland Industrial can handle the intricate downstream details that many other shops have to outsource. Midland being a one-stop-shop means you’ll receive a faster, more reliable path from concept to completion.

• • 3015 RI 9K Fiber Laser
  • High-precision processing of flat and shaped materials
  • Capabilities to cut 5′ x 10′ flat sheet metal, up to 1″ thick stainless steel
  • Able to cut carbon steel, aluminum, copper, brass, and titanium
  • Additional rotary head with capabilities to cut round tube, square tube, rectangle tube, angle iron, and c-channel 20′ long
  • Max size of 8″ round tube
  • Max size of 6″ square tube

Fiber laser, plasma cutting, and waterjet cutting are all commonly used in industrial fabrication to solve manufacturing challenges. Choose fiber laser for precise cutting of thin materials, high-volume production, complex designs, and clean finishes. Go with plasma cutting for speedy and cost-efficient cutting of thick metals. Waterjet cutting is the best choice for versatility, material flexibility,  and ultra high-precision cuts when speed is not a priority. 

Overall, the most important part of selecting which industrial cutting technique is best for your application is to make an informed decision. Understand your specific project requirements, budget, production volume, material types, and precision needs. Choosing the right industrial partner will help guide you through the decision process and ensure your industrial manufacturing goals are met. 

At Midland, we help clients across various industries move projects from concept to completion with confidence. Connect with Midland Industrial Services today to discuss the right cutting solution for your application.