Hypertherm Expands XPR Plasma Cutting Platform with New Productivity and Connectivity Features!

Hypertherm Associates has introduced a significant update to its XPR plasma cutting platform, adding a new range of productivity, quality, and connectivity enhancements aimed at helping fabricators achieve higher performance with greater consistency. The 2025 update strengthens the XPR family’s position as a versatile, next-generation plasma cutting solution by combining design simplification, improved process control, and intelligent digital integration.

A key upgrade is the introduction of a new control board that brings Ethernet LAN connectivity to the system. This enables IIoT-based monitoring, real-time data access, and seamless communication with industrial networks. With built-in support for MTConnect, operators and plant managers gain improved visibility into machine status, process performance, and system behavior, allowing for more accurate analysis and optimized decision-making on the shop floor. The interface tool can now be accessed directly through the network, simplifying system setup, diagnostics, and maintenance.

For fabricators handling simpler, repetitive tasks, Hypertherm has added Manual Set-mode—a valuable feature for operations that do not require CNC or PLC integration. This mode saves the previous settings even after the system is powered off, ensuring consistency between cycles and reducing downtime associated with reconfiguration.

The update also boosts gouging capabilities, enabling wider, deeper, and cleaner gouge profiles. These improvements help reduce weld preparation time significantly and minimize the need for secondary finishing operations. When paired with robots, cobots, or other automated motion systems, the enhanced gouging process becomes even more efficient. Extended arc stretch and increased transfer height allow the torch to reach into recessed or challenging areas, expanding the range of workable applications and improving accessibility in complex geometries.

Hypertherm has further strengthened high-amp performance in the XPR460 system. It now supports 460-amp nitrogen and Vented Water Injection (VWI) cutting, producing smoother edge surfaces on thicker stainless steel and aluminum materials. These capabilities offer fabricators the combination of high precision and surface quality needed for demanding applications. For mild steel, the updated 460-amp Y-Top True Bevel technology delivers better bevel accuracy and repeatability across thicker sections, reducing operator guesswork and improving first-cut success.

Together, these enhancements reflect Hypertherm’s continued commitment to advancing plasma cutting technology through smarter controls, enhanced digital connectivity, and improved process performance. The updated XPR family provides fabricators with a more capable, flexible, and efficient solution tailored to the increasing demands of modern metalworking environments.