When cutting steel plates, precision is everything. Whether you’re fabricating parts for construction, heavy machinery, or industrial applications, the cutting method you choose directly impacts accuracy, material waste, and production efficiency.

Two of the most common cutting methods are plate burning (oxy-fuel or plasma cutting) and laser cutting. But how do they compare in terms of tolerances? In this blog, we’ll break down the typical tolerances of each method, their advantages, and when to use them.

What Are Tolerances in Metal Cutting?
📌 Tolerance refers to the acceptable variation in a part’s dimensions after cutting. It determines how precisely a piece matches the required size in a drawing.

Tighter tolerances = More precision, but may require slower cutting speeds and higher costs.

Looser tolerances = Faster production, but less accuracy.

💡 Example: A part with a ±0.020” tolerance means its size can vary by 0.020 inches over or under the specified measurement and still be acceptable.

Now, let’s compare tolerances in plate burning vs. laser cutting.

Plate Burning (Oxy-Fuel & Plasma Cutting) – Typical Tolerances
Plate burning uses heat-based cutting methods to cut thick steel plates. The two most common techniques are:

1. Oxy-Fuel Cutting
Uses a flame and oxygen to melt and blow away metal.

Best for carbon steel plates thicker than 1/2″.

📏 Typical Tolerances:
✔ ±0.0625” (1/16”) to ±0.125” (1/8”) for most applications.
✔ Wider tolerance range for thicker plates (>1”).

💡 Best For: Heavy plate cutting, structural steel, shipbuilding.

2. Plasma Cutting
Uses high-velocity ionized gas (plasma arc) to cut metal.

Works on carbon steel, stainless steel, and aluminum.

📏 Typical Tolerances:
✔ ±0.030” to ±0.060” for plates under 1” thick.
✔ ±0.100” or wider for plates above 1.5” thick.

💡 Best For: Mid-range precision cutting of steel plates up to 2″ thick.

Laser Cutting – Typical Tolerances
Laser cutting uses a high-energy laser beam to vaporize metal, offering exceptional precision. It’s best suited for thinner materials but can also cut steel plates up to 1” thick.

📏 Typical Tolerances:
✔ ±0.002” to ±0.005” for plates under 1/2″ thick.
✔ ±0.010” to ±0.015” for thicker steel (up to 1” thick).

💡 Best For: Precision parts, tight-tolerance components, and intricate designs.

Plate Burning vs. Laser Cutting – Tolerance Comparison
Cutting MethodMaterial ThicknessTypical Tolerance RangeBest Application
Oxy-Fuel Cutting1/2” – 6”+±0.0625” – ±0.125”Heavy plate cutting, structural steel
Plasma Cutting1/4” – 2”±0.030” – ±0.100”Mid-precision steel cutting
Laser CuttingUp to 1”±0.002” – ±0.015”High-precision parts, intricate designs
Key Takeaways: Choosing the Right Cutting Method
1️⃣ Use Oxy-Fuel for thick steel plates (>1”) where high precision is not critical.
2️⃣ Use Plasma Cutting for mid-range accuracy on steel up to 2” thick.
3️⃣ Use Laser Cutting for the highest precision, especially for thin steel or intricate shapes.

By understanding tolerances and capabilities, you can choose the right cutting method for your project’s needs.

🚀 Need help selecting the best cutting method for your steel parts? Let’s talk!