Material Optimization with ProNest
ProNest advanced nesting software arranges parts on raw material to maximize sheet utilization. Features include common-line cutting (shared edges between adjacent parts), bridge cutting (connecting small parts to reduce pierce count), and dynamic nesting that adjusts in real time as parts are added or removed from the queue.
Customers report material savings of 5-15% compared to manual nesting, depending on part geometry complexity and mix. ProNest integrates directly with ERP and MRP systems, importing cut lists and exporting production reports. Compatible with plasma, laser, oxyfuel, and waterjet cutting tables.
- Common-line and bridge cutting for reduced cycle time
- Remnant tracking and inventory management
- DXF, DWG, and parametric part import
- ERP/MRP integration for production scheduling
Hole Quality with True Hole Technology
True Hole is a patented Hypertherm process available on HyPerformance HPRXD systems. It uses precisely controlled plasma gas, current ramping, and torch motion sequences to produce near-laser-quality holes in mild steel from 6 mm to 25 mm thickness.
The result: bolt-ready holes that eliminate secondary drilling on many structural and plate-work applications. Internal testing at Hypertherm's facility on 12 mm mild steel with the HPR260XD showed hole taper under 2 degrees and cylindricity within ISO 9013 Range 2 tolerances. Not all hole diameters and material thicknesses produce the same results; the best outcomes occur when the hole diameter is at least equal to the material thickness.
- Bolt-ready holes on mild steel 6-25 mm
- Automated gas and current sequencing
- Integrated into Phoenix CNC cut charts
- Eliminates secondary drilling on qualifying applications
Automated Bevel Cutting
Hypertherm bevel cutting solutions produce angled edges for weld preparation directly on the cutting table, eliminating manual grinding and torch beveling downstream. Available on HyPerformance plasma and fiber laser systems with 5-axis bevel heads.
Bevel angles up to 45 degrees on mild steel and stainless steel. The Phoenix CNC calculates torch offsets and kerf compensation for each bevel angle automatically, reducing operator setup time. Fabricators report eliminating 2-5 minutes of manual weld preparation per joint on structural steel connections, though savings depend on joint geometry and the operator's manual beveling speed before automation.
- V-bevel, Y-bevel, X-bevel, and K-bevel cuts
- Angles up to 45 degrees on steel and stainless
- Automatic kerf and offset compensation
- Reduces downstream grinding and weld prep labor
Process Control & Remote Diagnostics
The Phoenix CNC platform provides centralized process control for plasma, laser, oxyfuel, and waterjet cutting from a single interface. Automated gas selection, torch height control, and cut chart management reduce operator setup time and minimize human error.
Remote diagnostic capability allows Hypertherm service engineers to access system logs, monitor consumable wear, and troubleshoot issues without an on-site visit. This reduces downtime for many common issues from hours to minutes. In 2025, 62% of Hypertherm warranty service cases were resolved remotely, based on internal service data across 3,200+ documented tickets.
- Single-platform control for multiple cutting processes
- Automated cut charts reduce operator training time
- 24/7 remote diagnostics through secure connection
- Consumable wear tracking and predictive alerts