[Metal Massacre Fab Shop] has a review of a portable plasma cutter that ends up being a very good demonstration of exactly what these tools are capable of. If you’re unfamiliar with this kind of work, you might find the short video (about ten minutes, embedded below) to be just the right level of educational.

Plasma cutters work by forcing compressed air through a small nozzle, and ionizing it with a high voltage. This process converts the gas into a very maneuverable stream of electrically-conductive, high-temperature plasma which can do useful work, like cutting through metal. The particular unit demonstrated also has a rust removal function. By operating at a much lower level, the same plasma stream can be used to give an effect not unlike sandblasting.
Of course, an economical way to cut metal is to just wield a grinder. But grinders are slow and not very maneuverable. That’s where a plasma cutter shines, as [Metal Massacre Fab Shop] demonstrates by cutting troublesome locations and shapes. He seems a lot more satisfied with this unit than he was with the cheapest possible (and misspelled!) plasma cutter he tried last year.
And should you want a plasma cutter, and aren’t afraid to salvage components? Consider building your own.

Some people would love to test it in the Linux kernel 🤣 (sorry, had to do the joke)
Some people use lasers for rust removal:
https://hackaday.com/2016/03/17/laser-removes-rust-like-magic/
Some, yes. But this plasma cutter is about 350 bucks, and a laser rust remover is more dangerous and tens of thousands for a good one.
Not a hack
Just an ad.
Editor in Chief´s job is to remove comments like yours (and mine) that point such abuse out. Not to enforce any ethics rules.
Meh – I didn’t know you could use a plasma cutter to remove rust, so that’s both useful information and potentially going to inspire someone to hack up something that can do it DIY.
I’ve had one of these generic plasma cutters for a few years. Once you factor in 240V power and an air compressor, I’m not sure I’d consider it “portable,” but I guess we have to do what we have to for clicks
Keep extending the air hose and power cord 😂. It’s portable. Or mobile generator and compressor, it’s portable 😂
Portable, when it comes to plasma cutting and welding often means mounted to the back of a truck with long enough cables to reach whatever you’re working on.
“an economical way to cut metal is to just wield a grinder.”
I suggest that a plasma cutter is more economical. I’ll burn through $20 of cutting discs in an hour.
Those safes are pretty tough. :-D