EasyArc™ Plasma Cutting Cart

Pairing the ABB GoFa™ collaborative robot with the Hypertherm Powermax65 SYNC™, this mobile system delivers:

  • Up to 32mm recommended cutting capacity
  • RFID-driven automatic setup (no manual configuration)
  • Up to 3× longer consumable life
  • Single-cart, single power connection

Start producing consistent, repeatable cuts — without robotics expertise.

Robotic unstacking system for metal fabrication panels
Robotic unstacking system for metal fabrication panels

Plasma Cutting Configuration

Cobot Plasma Cutting. Rapid, Consistent, Safe.

The EasyArc Plasma Cutting Cart integrates the Hypertherm Powermax65 SYNC™ — Hypertherm’s most capable handheld/mechanized plasma cutter — with the ABB GoFa™ collaborative robot and EasyArc software. The result is a cobot plasma cutting system that any operator can run, with no cage, no G-code, and no robotics expertise required.

  • 32mm Recommended Cut
  • 50mm Severance Cut
  • 65A Max Output
  • 8 kW Power Output
  • 2×–5× Consumable Life
  • 480V Single Phase Setup

Built for Real-World Fabrication

Metal Fabrication

Consistent, repeatable cutting tasks with high precision — reducing errors and rework across carbon steel, stainless, and aluminum plate.

Pipe & Tube Cutting

Consistent and repeatable cuts and saddle cuts on pipe. Add the single-axis positioner for full-circle controlled rotation.

Custom & Small-Batch

Quickly adapt to different cutting patterns and materials — ideal for prototyping and bespoke manufacturing with fast changeovers.

Agriculture & Construction

High-precision cutting for farm equipment, structural steel, and heavy machinery components with consistent, repeatable results every cycle.

Why Cobot Plasma Cutting?

Productivity, precision, and process flexibility.

Precision & Consistency
Cobots follow highly accurate programmed paths — ensuring consistent, repeatable cuts and eliminating operator variability.

No Fatigue, No Bottlenecks
Cobots operate continuously without fatigue — skilled staff move into higher-value roles while the cobot handles repetitive cutting.

Versatile, Low Learning Curve
No significant capital outlay or lengthy integration. Platform versatility supports cutting, gouging, flush cutting, and extended reach applications.

Reduced Secondary Operations
The accuracy from the Powermax SYNC minimizes post-process grinding, rework, and cycle time.

300%

Productivity Increase – HyperTherm Customer Case Study

2x

Consumable Life vs. Standard Plasma

5x

Consumable Life vs. Competitors

Robotic unstacking system for metal fabrication panels

Plasma Parameter Setup

Smart Parameter Selection.

Plasma parameters — amperage, arc voltage, pierce delay, cut speed — must be dialed in precisely for each material and thickness. EasyArc handles this automatically, pulling from proven Powermax SYNC parameter tables. Full manual adjustment is always available.

Parameter EasyArc / Powermax Handling
Material Mild steel, stainless steel, aluminum
Material Thickness Select from predefined thickness ranges
Cut Amperage Auto-set via SmartSYNC RFID cartridge; adjustable
Process Mode Auto-set: cut, gouge, FineCut, FlushCut
Arc Voltage / Height Automatic torch height control during cutting
Cut Speed Defined via robot path programming
Pierce Delay Auto-configured per material and thickness
Part Searching Enabled / disabled per program step

EasyArc Software

Expert Precision, No Coding Required.

EasyArc software removes the traditional complexity barrier from welding. Operators teach weld paths by physically guiding the robot arm — no laser optics knowledge or specialized training required.

  • Guide the robot arm to each weld position — positions recorded automatically
  • Select weld type from the comprehensive command library
  • Choose material and thickness for automatic laser parameter setup
  • Seam tracking follows the weld joint precisely even with part variation
  • Part searching compensates for positional offset at the start of each cycle
  • Save programs for instant recall and repeat production

Powermax65 SYNC™ Specifications

The Smarter Choice for Cobot Plasma.

The Powermax SYNC series was purpose-built for a cartridge to automatically configure the power supply to match torch-loaded consumables.

For cobot integrators, this means simpler setup, fewer errors, and a smartphone app to monitor starts, transfers, and cut quality in real time.

RFID-Enabled Cobot Integration

The Hypertherm cartridge RFID chip feeds process data to EasyArc, which automatically configures the torch and eliminates the variability introduced by manual setup.

Single-Piece Cartridge Consumables

Color-coded by process for instant identification — drag cutting, mechanized/standoff cutting, max removal gouging, max control gouging. End-of-life detection tells the operator exactly when to change. Available at 45A, 65A, and 105A amperages. No traditional 5-piece stack-up, no assembly errors, no premature stoppage.

Standard System Specifications

Cutting Capacity — Powermax SYNC
Cutting Performance Thickness Cut Speed
Recommended 32mm (1¼”) 500 mm/min / 20 ipm
38mm (0-02″) 250 mm/min / 10 ipm
Severance 50mm (2″) 125 mm/min / 5 ipm
Pierce 22mm (7/8″) With auto height control
Gouging Capacity
Cutting Performance Thickness Cut Speed
Recommended 32mm (1¼”) 500 mm/min / 20 ipm
38mm (0-02″) 250 mm/min / 10 ipm
Severance 50mm (2″) 125 mm/min / 5 ipm
Pierce 22mm (7/8″) With auto height control
Electrical & Physical Specifications
Input Voltages 200-480 V, 1-PH, 50/60 Hz

200–600 V, 3-Ph, 50/60 Hz
Kilowatt Output 9 kW
Input Current 200/208/240/480 V, 1-PH 52/50/44/22 A @ 9kW

200/208/240/480/600 V, 3-PH 32/31/27/13/13 A @ 9 kW
Output Current 20–65 A
Rated Output Voltage 139 VDC
Duty Cycle 50% @ 65 A, 230-600 V, 1/3-PH

40% @ 65 A, 200-208 V, 1/3-PH

100% @ 46 A, 230-600 V, 1/3-PH
Open-Circuit Voltage 295 VDC
Dimensions with handles (D×W×H) 483mm D; 233mm W; 430mm H / 19″ D; 9.2″ W; 17″ H
Weight 29 kg / 61 lbs.
Gas Supply Clean, dry, oil-free air or nitrogen
Gas Pressure Optimum: 7.6–8.3 bar (110–120 psi)

Minimum: 5.2 bar (75 psi)
Gas Flow Rate Cutting: 250 l/min @ 5.9 bar (450 scfh, 7.5 scfm @85 psi)

Gouging: 250 l/min @ 4.8 bar (450 scfh, 7.5 scfm @70 psi)
Power Supply Type Inverter — IGBT
Input Power Cable Length 3 m (10′)
Engine Drive Requirement 15 kW for full 65 A output
Certifications CSA-certified for use in the Americas and Asia (except China)
Warranty 3-year power supply · 1-year torch

Hypertherm Associates has over 50 years of plasma technology expertise and is the industry benchmark for cobot plasma integration. Powermax SYNC supports handheld, mechanized, and robotic torch configurations.

  • Integrated torque sensors — superior power and force-limiting performance
  • Safety certified to Category 3, PL d — works alongside operators without fencing
  • TCP speed up to 2.2 m/s
  • 1050mm reach — 12% longer than comparable 5 kg collaborative robots
  • Powered by ABB OmniCore controller

Optional upgrade to 10 kg / 1920mm reach long-arm variant — see Options section.

  • Powder-coated steel frame for durability and mobility
  • Swing-arm mount for the T45 Positioner
  • Integrated robot controller within the cart
  • Bluco modular fixturing tabletop 1000mm × 1500mm — ±0.005″ repeatability
  • Locking casters for repositioning across the shop floor
  • Single 480V 3-phase power drop required
  • 1-year warranty included

Options & Upgrades

Configure for Your Application.

ABB GoFa™ 10 kg / 1920mm Long-Arm Upgrade
Extends reach to 1920mm and increases payload to 10 kg for a larger working envelope on larger plate sections and complex cut geometries. Includes upgraded mounting plate.

Fume Extraction — Robovent FE860
Plasma cutting produces significant fumes and metal particulate. Repositionable tabletop nozzle captures fumes at source. Runs on 115 VAC from the cart’s single power drop.

Fume Extraction — Robovent ProCube II
Higher-capacity fume extraction for high-production plasma cutting. Longer filter life than the FE860 for demanding production environments. Requires a separate power drop.

Dual-Station System Configuration
Adds a second 1000mm × 1500mm Bluco table with arc current between stations. Load and position the next part while the robot is cutting — maximizing production uptime.

Easy Reach — Collaborative Robot Rotary Boom
Extends the robot’s working envelope 1.5 meters via a manually-rotated boom cantilevered off the cart. Rotates in 45° increments for positioning over large plates.

Collaborative Robot Manual Travel Track — 3.1m
Manually adjustable linear track for extended coverage across long plate sections or multiple fixtures. Pricing available upon request.

Laser Enclosure
A 12’×12′ laser-safe enclosure with a 90″ double-hinged main door for easy cart and pallet access, plus a sliding 48″×60″ half door with a 12″×12″ laser window for operator load/unload without entering the enclosure. Includes all panel hardware, floor-mount anchors, and two door interlock safety switches for integration with the laser safety input.

* Installation is available at an additional cost.

EasyArc Start — 3 Days On-Site Support
Three days of on-site setup, training, and programming support from an MWES automation technician for a smooth system launch. Travel time and expenses included.

Additional Week of Support — 5 Days On-Site
Extends on-site support by five days for additional training or programming assistance. Travel time and expenses included

Ready to Automate Your Plasma Cutting?

Fast deployment | Minimal training required | Proven productivity gains

Get a system configured for your materials, production volume, and shop layout.