There are some cases, as I said previously, where a cheaper purchase price may be the best decision on a plasma cutter, just as it may be with any other tool.
A few years ago (actually about 30 years!) I was pretty young and had a passion for metal fabrication. I worked for a small company in NH that had 11 employees, that produced 1 product, a 1000 Amp mechanized only plasma cutter that could cut 6" aluminum and stainless. We worked hard, built about 3 of these systems a month, and didn't make much money. When I went home, and on weekends I worked in my garage building racecars, trailers, tractor implements with my low cost used and cheap import welding and cutting equipment (there were no hand held plasma's that could run on air and single phase power at the time). I bought cheap tools, and searched for used equipment that I could fix up...so that I could work (play) in my shop in my spare time.
Today Hypertherm has over 1200 employees (all have stock in the company), we have over 35 different plasma cutting products, and are (by far) the largest manufacturers of plasma cutting equipment in the world. We can produce in the range of 5000 plasma systems a month. I still work hard, and I make a bit more money, and I still have a passion for metal fabricating. My home shop is bigger, I can afford better tools, and someday my sons will own all of the equipment. I buy equipment that works as advertised, that will last and have parts available for many years, and that I expect my sons to be able to get some use out of.
So....when you talk pricing and performance on major tools such as a plasma cutter or a welder....the above types of life situations certainly have an effect on the amount you pay. The other alyternative to buying low cost import equipment (which means sending your money to another continent!) is to use the internet and find good used equipment from a major supplier that can meet all your criteria for use. I still buy used equipment if it is a major brand....just bought a 6 year old Miller 250 Amp Mig for far less than an import....and I am very sure that service and parts will be available for a long time!
Plasma systems (power supplies and torches) are not all alike. 60 Amps on one model does not cut like 60 Amps on another model, trust me. There are major engineering breakthroughs in torch technology that occur monthly....but only from the companies that make a big investment in that engineering. When the patents expire 13 to 17 years later, the other manufacturers can catch up. The breakthroughs involve higher energy density, better control of cut angularity, faster cut speeds at a given amperage, better piercing capability, ease of use, reliability, and of course...lower operating cost.
Most of the import plasma's use torch designs that are copies of older technology. One of the most common import plasma torches is a copy of an over 30 year old Esab PT31 torch! Another is of an almost 20 year old Trafumet (italian) torch design. Even some of the major plasma system producers only come up with new torch designs every 10 to 15 years.
Hypertherm has over 75 plasma patents, mostly on torch and consumable designs, but others are related to gas flow control, power supply output control, all of these technology breakthroughs are to improve performance, reliability and to lower the cost of operation.
So, to conclude:
- yes Jim Colt (Me) may be biased on his first choice for plasma cutting...but he has been around, and can offer good advice....which is what this thread's original poster was looking for!
-Try out a few different plasma systems on the thickest and thinnest materials you are going to cut. Your local welding supply store is a good place. You also can go to the manufacturers and ask for a specific cut sample....or better yet ask me. I'll cut a part and post a picture for everyone!
-Make your price decision based on whhat you are going to use it for, how long you plan to keep it.
- Don't forget....there are a lot of good used plasma systems out on the market. Craigslist is a great source. If anyone finds a used Hypertherm, contact me and I'll tell you what it is worth, or I may even tell you to steer clear (depending on vintage and model!)
- It is not Amps that does the cutting.....it is Load Voltage X Amps, which equals killoWatts. The best systems may have a lower amperage rating, but will have a higher killowatt rating, duty cycle rating, and a better technology torch.
Jim Colt
) but just like anything I bought in the past I usually go over board 
