Hypertherm Associates, a U.S.-based leading manufacturer of industrial cutting systems and software, will showcase a variety of precision plasma and waterjet cutting technology along with production-enhancing software and digital solutions at FABTECH 2025, Sept. 8-11, in booths A4513 and B15051 at McCormick Place, Chicago, Illinois. In addition, Hypertherm Associates’ subject matter experts have been selected to present professional development educational sessions during the conference which occurs concurrently with the show.
A new feature to the company’s booth in the Forming and Fabricating Hall (A4513), Hypertherm will introduce a hands-on applications zone that proves plasma’s cutting versatility and technologies can benefit virtually every manufacturing sector. Visitors can handle real-world parts highlighting plasma cutting capabilities that include gouging, beveling, flush cutting, trimming and more. Cobot plasma simulations will drive home how easy it is to integrate plasma into automated production systems.
For gouging and flush-cut applications, the Hypertherm Powermax SYNC Series will be on display. The Powermax45 SYNC is the best investment for gouging, cutting and marking applications and features built-in intelligence, a patented single-piece cartridge and up to five times longer consumable life with greater cutting power than its higher-amperage competitors. The Powermax45 SYNC is easy to use and designed to simplify operations, maximize performance and boost productivity. The Powermax85 SYNC is Hypertherm Associates’ next-generation professional-grade air plasma cutter that simplifies gouging operations and is recommended for cutting thicknesses up to an inch. It features an automated system process set-up via advanced RFID-enabled SmartSYNC torches and a revolutionary single-piece cartridge consumable that provides trackable utilization data.
Additionally, booth visitors will experience the latest addition to the company’s XPR line with X-Definition technology, which will include new features seen for the first time at the show. The XPR460 provides unmatched cut quality on mild steel, stainless steel, steel and aluminum. The unit performs multiple applications with SureCut technology for bolt-ready holes and smooth 45-degree bevels. Hypertherm SureCut also includes PlateSaver technology that combines XPR arc stability and moving pierce to minimize part separation and increase material utilization by as much as 14% for lower cost per part. The XPR460 is well suited for robotic cutting applications and is future-enabled for Smart Factory integration and connectivity.
Also featured in booth A4513 will be Hypertherm Associates’ OMAX waterjet cutting technology. FABTECH attendees will be the first to experience the North American debut of OMAX’s latest innovation in abrasive waterjet technology, a system purpose-built to meet the needs of manufacturers.
In addition, OMAX will bring examples of the company’s broad portfolio of waterjet machines to show guests, including the OptiMAX and ProtoMAX waterjet cutting systems.
OptiMAX is the world’s most accurate waterjet and represents the culmination of three decades of waterjet engineering and expertise. OptiMAX comes standard with the exclusive IntelliTRAX linear drive system that provides real-time, closed-loop positioning feedback and is backed by the industry-leading IntelliMAX Software Suite premium software. The IntelliMAX software is a highly advanced, yet intuitive CAD/CAM system that runs on Windows 10 and quickly converts designs into machined parts. At FABTECH, the machine will feature a taper-eliminating Tilt-A-Jet cutting nozzle that moves the taper to the scrap part for exact square edges on the workpiece.
FABTECH attendees will also see the company’s VersaJet cutting nozzle in a live cutting demonstration. VersaJet has a cutting range of 0 to 60 degrees for 5-axis cutting of beveled edges, angled sides, countersinks and 3D shapes. Fully software-controlled, VersaJet virtually eliminates taper on finished parts with automatic taper compensation.
OMAX will also feature its compact, economical ProtoMAX cutting system at FABTECH 2025. For prototyping and low-volume production, ProtoMAX provides a sleek 12" x 12" (304 mm x 304 mm) cutting envelope for materials up to 1" (25 mm) thick and comes with everything necessary to start cutting after fast, easy installation.
In addition to cutting technology hardware and accessories, Hypertherm Associates will feature several automation and digital solutions to enhance productivity and streamline operations. For example, OMAX Order is an innovative mobile app that makes service and support available on smartphones and tablets. OMAX Order is designed for simplicity and streamlines part ordering for OMAX waterjet machines.
Engineers will be on hand to demonstrate Hypertherm Associates’ ProNest and Robotmaster software systems. ProNest CAD/CAM nesting software is designed for advanced mechanized cutting applications, including plasma, laser, waterjet and oxyfuel. The software offers standard features that include part design, CAD import, manual nesting, reporting, costing and quoting, and its fully automated interface reduces programming time from hours to minutes.
Booth visitors will also learn how Robotmaster offline programming (OLP) software blends a powerful tooling editor, trajectory, CAD/CAM and multiple cell functions that are essential for complex applications and shapes. Intuitive features enable users of all experience levels to program with confidence. Robotmaster OLP cuts programming time, streamlines workflows and seamlessly blends robot programming, simulation and code generation for quicker, error-free results and greater productivity.
Hypertherm Associates subject matter experts will also be featured speakers at the FABTECH 2025 conference.
Hypertherm Director of Product Marketing Strategy, Waterjet, Arion Vandergon will educate attendees on technology advancements that offer solutions to production challenges with his presentation on “Waterjet Insights for the Masses and Evolution of Connected Systems and Insight Delivery.” Similarly, Natalie Adams, Hypertherm Product Marketing Manager, Integrated Cutting Solutions, will apply her expertise to inform industry leaders on “Enhancing Manufacturing Efficiency with Solutions for High-Mix Production.”
Joining Vandergon and Adams on the speakers’ roster will be Hypertherm Product Marketing Manager, Software, Tom Stillwell and Harry Mellott, Project Manager, Marketing. Their “Cutting-Edge Advancements in Mechanized Plasma Cutting" conference session will bring practical solutions to life for fabricators through ongoing innovations.
To experience the versatility and creativity possible with plasma cutting, FABTECH 2025 attendees can watch world-renowned metal artist Rae Ripple demonstrate her craft using a Hypertherm Powermax45 SYNC plasma cutter in the Welding Hall at booth B15051. Ripple, her art and inspirational story have been featured prominently in magazines, on television and in documentary films.
