Welding & Fabrication worked example

Plasma Cutting Cost with parts cut on the job of 80 parts: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop parts cut on the job to 80 parts, then walk the calculation through step by step. Estimate plasma cutting cost from pierce-and-cut count, per-part consumable cost, gas and electricity, and labor.

The inputs for this scenario

  • Parts cut on the job: 80 parts (the input this scenario stresses; the baseline uses 160)
  • Per-part plasma consumables and power: 0.85 $ / part (held at the documented default)
  • Plasma gas and torch setup cost: 120 $ (held at the documented default)
  • Operator labor with burden: 285 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total plasma cutting cost = parts cut on the job × per-part plasma consumables and power + plasma gas and torch setup cost + operator labor with burden.
  • Total plasma cutting cost works out to 473 $ at these inputs, and this is the headline figure for the scenario.
  • Plasma cutting cost per part works out to 5.91 $ / piece at these inputs.
  • Per-part plasma consumables and power works out to 68 $ at these inputs.
  • Gas, torch setup, and operator labor works out to 405 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where parts cut on the job sits at 160 parts and the headline result is 541 $, this scenario comes in 12.57% below the baseline at 473 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to parts cut on the job, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes your per-part consumables figure already reflects real electrode and nozzle life at your amperage; if you plug in optimistic consumable wear, the per-part cost will read low.

Results at a glance

  • Total plasma cutting cost: 473 $ (headline result)
  • Plasma cutting cost per part: 5.91 $ / piece
  • Per-part plasma consumables and power: 68 $
  • Gas, torch setup, and operator labor: 405 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Plasma Cutting Cost calculator, set parts cut on the job to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.