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Free Hypertherm Consumables: Fall 2026 Savings

10/1/2026

If you've had your eye on a Powermax45 SYNC or a Powermax65 SYNC then this fall is time to make your move! With your purchase of a new Powermax45 SYNC or a Powermax65 SYNC from us, you'll get your choice of 3 FREE consumables for handheld or mechanized systems!

This deal is a limited time offer, only available from October 1st, 2026 until December 31st, 2026! Claim your free consumables bundle before the opportunity is gone. Get the full details on how to redeem this deal below.

QUALIFYING Machines

Powermax45 SYNC– Handheld
Powermax45 SYNC– Mechanized

APPLICATIONS:

drag cutting
fine feature cutting
max control gouging
max removal gouging
mechanized cutting
marking

FIND IT IN STORES

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Powermax65 SYNC– Handheld
Powermax65 SYNC– Mechanized

APPLICATIONS:

drag cutting
extended reach cutting
extended reach gouging
fine feature cutting
flush cutting
max control gouging
max removal gouging
mechanized cutting

FIND IT IN STORES

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Promotional Package Items
(Pick 3 during claim process)

Part #	PACKAGE OPTIONS: POWERMAX45 SYNC - HANDHELD	VALUE
428927	SmartSYNC or Adapter 45A Drag Cutting	$56
428928	SmartSYNC or Adapter 30-45A Hand FineCut	$58
428984	SmartSYNC 65A HyAccess Drag Cut	$129
428987	SmartSYNC 65A HyAccess Gouge	$129
428933	SmartSYNC or Adaptor 45-85A Max Control Gouge	$60
428932	SmartSYNC or Adaptor 45-85A Max Removal Gouge	$60
428932	SmartSYNC 65A Flushcut	$107

Part #	PACKAGE OPTIONS: POWERMAX45 SYNC - MECHANIZED	VALUE
428927	SmartSYNC or Adapter 45A Mechanized Cutting	$56
428928	SmartSYNC or Adapter 30-45A Mechanized FineCut	$58
428984	Hypertherm Cartridge Reader	$52

Part #	PACKAGE OPTIONS: POWERMAX65 SYNC - HANDHELD	VALUE
428931	SmartSYNC or Adapter 65A Drag Cutting	$58
428928	SmartSYNC or Adapter 30-45A Hand FineCut	$58
428984	SmartSYNC 65A HyAccess Drag Cut	$129
428987	SmartSYNC 65A HyAccess Gouge	$129
428933	SmartSYNC or Adaptor 45-85A Max Control Gouge	$60
428932	SmartSYNC or Adaptor 45-85A Max Removal Gouge	$60
428952	SmartSYNC 65A Flushcut	$107

Part #	PACKAGE OPTIONS: POWERMAX65 SYNC - MECHANIZED	VALUE
428930	SmartSYNC or Adapter 65A Mechanized Cutting	$58
428926	SmartSYNC or Adapter 30-45A Mechanized FineCut	$58
528083	Hypertherm Cartridge Reader	$52
428925	SmartSYNC or Adapter 45A Mechanized Cutting	$56

HOW TO REDEEM YOUR CONSUMABLES PACKAGE:

Purchase a new Powermax45/65 SYNC from one of our locations in Maryland or Pennsylvania, at any time between Oct 1, 2026 and Dec 31, 2026.
Save your receipt, find the serial number for your new machine, and register your machine on Hypertherm's website to claim your chosen consumables bundle!
Sit back and relax while you wait for your free gifts to be delivered to your door!

CLAIM YOUR FREE CONSUMABLES PACKAGE

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From Cylinders to Bulk: Building a Better Gas Supply System for Ritner Steel

9/4/2026

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In a busy shop, running out of gas isn’t just a minor inconvenience. Industry estimates suggest that swapping an empty cylinder can take approximately 25 minutes each time, during which production may be interrupted.

At Ritner Steel in Carlisle, Pennsylvania, shielding and cutting gases are essential to daily structural steel production. As production demands increased, individual high-pressure gas cylinders consumed more time, labor, and valuable floor space.

Ritner needed a gas supply that could keep pace without adding to employees’ workload. So the Earlbeck team designed and installed a bulk gas system to reduce cylinder management and keep production moving.

Ritner Steel utilized individual high-pressure cylinders to supply gases for welding and cutting operations. With multiple cylinder changeouts each day, interruptions could quickly add up to hours of lost production time and employee labor spent managing gas instead of keeping fabrication moving.

Ritner needed a gas supply capable of keeping pace with production without creating more work for employees.

What we wanted to deliver was a gas delivery system designed around how their shop actually operates. Freeing up valuable floorspace, removing unnecessary risk to employees and turning daily work tasks into invisible infrastructure that quietly does its job in the background without need for employee intervention.

Earlbeck designed and installed a comprehensive bulk gas supply system with bulk liquid argon and CO₂ for their welding needs, and bulk liquid nitrogen and oxygen for their cutting needs.

But installing larger tanks was only part of the solution. These bulk gases are connected to centralized distribution piping that runs directly to the production areas, maintaining a continuous and dependable gas supply for welding and cutting operations.

This centralized system uses internet-based monitoring technology to track their gas supply. When replenishment is needed, an order can be placed automatically. Employees no longer need to continually check gas levels, remember when it’s time to reorder, or wait for a last min emergency cylinder delivery.

All of those changes add up to a cleaner workflow and a safer production environment where employees can spend more time focused on fabrication!

The RESULTS & BENEFITS

Fewer Production Interruptions
Routine cylinder changeouts no longer interrupt welding and cutting operations, allowing employees to stay focused on productive fabrication work. Wireless telemetry monitoring triggers reorder before supply runs low, helping prevent unexpected gas shortages that could disrupt work.
Less Time Spent Managing Gas
Monitoring inventory, placing orders, and managing routine gas replenishment are removed from the team’s daily to-do list, reducing the time employees spend on gas supply management.
Safer Employees
With fewer individual cylinders to move, replace, and store, employees face less exposure to the hazards associated with handling high-pressure cylinders such as dropped or falling tanks.
More Usable Floor Space
In busy fabrication shops where every square foot matters, space previously dedicated to cylinder storage and staging can be returned to productive use.

READY TO DITCH THE CYLINDERS?

If cylinder changeouts, gas inventory and ordering, and storage are becoming part of your production headaches, it may be time to rethink how gas moves through your facility.

Your operations shouldn't have to struggle because the current gas supply no longer matches production needs. Talk to the Earlbeck team about your current gas setup and find out where your operation could save time, space, and unnecessary handling.

With our complimentary Gas Application Analysis, we can evaluate your gas usage and production requirements to determine whether a bulk or centralized gas delivery system makes sense for your facility, FOR FREE!

REQUEST YOUR FREE GAS APPLICATION ANALYSIS!

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Stop Burning Through Your Plasma Consumables!

8/27/2026

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When shops look for more productivity from a high-definition plasma cutting system, cutting speed usually gets most of the attention. How many inches per minute can you cut? How quickly can you move from one part to the next?

But there's another part of the cutting cycle that deserves just as much attention: the pierce.

Every time a plasma torch starts a cut in the middle of a plate, it has to pierce completely through the material before moving along the programmed cut path.

During those few seconds, the displaced molten metal has to go somewhere, and much of it is being forced back toward the torch. That molten material can shorten your consumable life, affect cut quality, and add unnecessary time and cost in rework.

So, if it feels like your plasma consumables aren't lasting as long as they should, the consumables themselves might not be the problem. Your piercing process could be!

So why is plasma piercing so hard on consumables? Well, let's think about what happens when you pierce a piece of plate.

Your plasma arc begins heating and melting the metal, but until it penetrates all the way through, that molten material can't escape through the bottom of the plate, so it tends to travel upward, splashing toward your nozzle and other torch components. When you are cutting plate throughout a shift, that exposure is repeated every time the torch starts another pierce.

That's why pierce height matters.

Some modern plasma power sources have the ability to transfer your arc from much higher, and starting farther away from the plate gives that molten metal more room to disperse instead of sending as much of it toward the consumables. Once the arc has completely penetrated the plate, your torch can descend from its pierce height to a normal cutting height and start moving along your cut path.

The process happens quickly, but getting that sequence right can have a real impact on your consumable life.

Six Ways to Reduce the Stress of Piercing

Chain cutting

Chain cutting keeps the torch on as it cuts through the scrap metal between one nested part and the next. Instead of stopping and piercing the plate again for each part, it cuts through the material connecting them. Fewer arc starts mean fewer pierces and less consumable wear.

However, it works best for simple parts because holes, slots, and other internal features still require separate pierces.
Part geometry and nesting software may also limit where this technique can be used. When planning a group of parts, look for opportunities to reduce unnecessary pierces where feasible.

Edge Starting

Starting at the edge of the plate can help protect your consumables. Because the torch isn't piercing through the middle of the material, molten metal is directed away from the torch rather than forced back toward it.

Edge starting can be challenging on an automated table because the plate edge may not be in exactly the same position each time. The operator or system must position the torch accurately. For this reason, edge starting is most practical when cutting material near the system’s thickness limit OR when the setup can be performed consistently.

Pre-Piercing

Instead of asking the plasma torch to pierce every starting point, holes are created in the plate before plasma cutting begins.

The torch can then start its cut at the pilot holes you made, essentially giving it an internal "edge start".

This approach can reduce the stress associated with piercing thick material, but positioning becomes critical.

The plasma torch needs to locate the pre-pierced hole accurately enough to establish the arc where intended.

So, while pre-piercing can solve one problem, it introduces another consideration: repeatable positioning.

Double Piercing

If you're cutting thick plate and edge starting doesn't make practical sense for the application, then you might want to try a double pierce.

It's kinda in the name, but we'll explain it anyway.
What you'll want to do is pierce only partway through the material, then remove the created slag, and run your second pierce all the way through.

That first partial pierce creates an area that can help redirect molten metal away from the torch while the second pierce is running.

This technique also requires accurate torch positioning and an operator or system capable of repeating the process reliably.

Moving pierce

Now this technique requires some finesse. Instead of just keeping the torch stationary while it penetrates the plate, your torch is going to begin moving right after the arc transfers.

Because the torch is moving, molten metal can trail behind it rather than splashing directly upward toward the torch body. The arc will penetrate progressively as the torch travels.

Travel speed is important here, because the torch has to travel far enough to complete the pierce without transitioning into the normal cutting process too soon. You also have to leave enough room in your nest layouts to account for that lead up.

In other words, moving piercing can provide benefits, but those benefits depend heavily on operator skill, programming, and (again) consistency.

advanced piercing technology

Hypertherm has developed several technologies to help protect consumables and increase piercing capacity on certain plasma systems.

Argon-assisted piercing sustains the arc over a greater distance, allowing it to transfer from a higher pierce height and reducing molten-metal damage.

PowerPierce uses liquid-cooled shielding to prevent molten metal from sticking to the nozzle. It can be used alone or with argon-assisted piercing to extend consumable life and reduce the need for edge starts.

Depending on the Hypertherm system and application, PowerPierce may be used alone or with argon-assisted technology. Together, these features can increase piercing capacity and, in some applications, reduce the need for edge starts.

HyPilot Cartridge

The HyPilot cartridge is purpose-built for industries such as structural steel, pipe and tube, pressure vessel, and automotive manufacturing, which often require applications with high pilot arc time to optimize productivity and avoid downtime, making consumable longevity a critical factor in overall system performance.

Designed specifically for robotic and cobot plasma cutting environments, the HyPilot cartridge addresses the unique demands of 3D applications such as cast trimming, where prolonged pilot arcing and higher stand-off heights accelerate consumable wear. When incorporating advanced, patent-pending NickelPlus® technology for continuous pilot arcing applications, the cartridge delivers at least twice the life of standard 105-amp mechanized cartridges, reducing operating costs without sacrificing productivity or cut quality.

As manufacturers increasingly adopt robotic plasma cutting because of its flexibility and speed compared to traditional methods, the HyPilot cartridge builds on that value by lowering the total cost of ownership.

A plasma consumable is like any consumable, eventually it has to be replaced. That's just part of the process. How quickly it needs to be replaced is another story.

Piercing puts some of the greatest stress on a plasma torch during the entire cutting cycle. The right pierce height, timing, cutting strategy, and equipment can help control that and keep your consumables productive for longer.

But it's only one part of the equation. Saving a few seconds on cutting time doesn't mean much if you're only going to lose that productivity to premature consumable changes, excessive grinding, recuts, or machine downtime. An impressive cut speed doesn't mean much if the process can't produce acceptable parts consistently throughout a shift.

A good plasma process needs to balance cutting speed, piercing time, consumable life, cut quality, part repeatability, operator involvement, and overall cycle time.

If you're replacing plasma consumables more frequently than expected, struggling with thick-plate piercing, or trying to improve your plasma cutting productivity, Earlbeck can help you take a closer look at the complete process.

Talk with our team about your plasma application, equipment, and consumables, and we'll help you find ways to get more productivity from every cut!

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Buying Metal for Your Next Project? A Guide for Hobby Welders and Fabricators

7/9/2026

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You really can’t show up at a metal supplier’s warehouse and just ask for “some steel tubing."

Well… you can, but it's a bit like walking into a restaurant and asking the waiter for "some food." You might get a meal, but chances are it won't be the one you had in mind.

Fortunately, buying metal isn't nearly as intimidating as many first-time fabricators think. Once you understand a handful of basics such as how different shapes are measured, what common material grades mean, and the information your supplier needs before cutting an order, you'll be able to walk into almost any steel warehouse with confidence.

Better yet, you'll avoid one of the most common (and expensive) beginner mistakes: buying the wrong material and discovering the problem only after you've started cutting or welding.

In this guide, you'll learn:

Which measurements suppliers actually need before they can fill your order
The difference between tubing and pipe (they are not one and the same)
When A36, 304 stainless, or 6061 aluminum is the better choice

METAL SHAPES

Knowing the basics before contacting a supplier can save a surprising amount of time and prevent ordering mistakes. So let's talk about some standard shapes and lengths, what measurements are necessary for ordering, and how to take those measurements correctly.

FLAT BAR

These pieces typically come in standard 20' sections, and you'll need the specifics for the width and thickness.

SOLID STOCK

These also typically come in 20' sections, but you'll need to know the diameter and the shape.

Angle IRON

These pieces tend to be sold in 20'-40' sections and they have two clear sides that aren't always equal. You'll need those two side measurements, plus the thickness.

SQUARE TUBING

These are generally sold in 20', 24', or 40' sections, with your width/height side measurements being equal, because it is a square after all. You'll also need to measure thickness here too.

Rectangle tubing

Not all that different than your square tubing, coming in standard 20', 24', or 40' sections, you'll need your side measurements (which won't be equal this time) as well as the thickness.

Round Tubing

Again, generally sold in 20-40' sections, for round tubing you're gonna need to know the outside diameter measurement of your tube, as well at the thickness.

PIPE

While pipe is similar to tubing, it actually follows a different set of rules that can be a little confusing. For pipe you'll need to know your nominal pipe size (NPS) and your schedule number.

Because pipe typically has something run through it (think steam, water, etc), different applications call for different wall thicknesses. This is where schedule numbers come in to play. Schedule numbers are what indicate pipe wall thickness. The higher the schedule number, the thicker/stronger the pipe.

And because pipe needs to connect, you'll want the outside diameter of your pipes to match up. This is where NPS comes in.

The part that may trip you up is:
Smaller pipe that's 12" and under is measured from the inside diameter.
Larger pipe that's 14" and over is measured from the outside diameter.

For larger pipe it's easy, your outside diameter and your NPS are going to be the same number. But for smaller pipe that's measured from the inside diameter, you'll need to consult a standardized chart like this one from Metal Supermarkets to figure out your NPS.

Pipe typically comes in 20' or 40' sections and your average pipe, used for things like general plumbing, water lines, or light-duty industrial is gonna be SCH 40.

Sheet Metal

The way this is measured is by the thickness of the sheet, represented in gauges with a higher number gauge being thinner material and a lower number gauge being thicker material.

You will usually see sheet metal come in options between 30-7 gauge and to figure out what you need, you need to first know what metal you're using, and then you can consult the corresponding gauge chart for that specific metal.

Metal Plate

Once you reach about 6 gauge, you get into plate, and for plate, we are going to be measuring thickness in inches.

Again, this depends on what type of metal you're working with but plate usually starts at about 3/16" and goes up from there.

Both plate and sheet are generally sold in 4' x 8' sections, but larger pieces are available.

MATERIAL GRADES

Not all metal is created equal, so let's talk material grades. Each grade has different chemical properties that dictates the weldability, and this info will help you pick the right filler metal and the right welding process. While there's a wide variety of metals available, the most common ones you'll run into here are carbon steel, stainless steel, and aluminum.

Carbon steel

Carbon steel is graded by the amount of carbon in it and for most fabrication projects, A36 steel is a great choice. It's a pretty versatile workhorse that's affordable, widely available, and welds well. What more can you ask for?

But as your structural requirements ratchet up, you will need higher-strength materials, like A572-50, that are designed for heavier loads and more demanding applications.

Stainless steel

Stainless steel is graded by its crystalline structure and alloy composition, and it's a fan favorite for aesthetic reasons and it's corrosion resistance. The two most common grades you’ll encounter are 304 Stainless and 316 Stainless.

For general fabrication, 304 is sufficient, but if you're worried about moisture, salt, or chemical exposure, then 316 will offer that extra protection you need.

Aluminum

Like stainless steel, aluminum offers excellent corrosion resistance, plus it's got a great weight-to-strength ratio, remaining lightweight while still being strong. The most common grades you'll run into here are 1100, 2024, 3003, 5052, and 6061.

If you're looking for a soft and formable option, then commercially pure 1100 aluminum is a great choice. For a little higher tensile strength but less corrosion resistance, go with 2024. For something that offers a lot of versatility when it comes to welding processes, 3003 is a strong option.

Now if you're looking for something that's even stronger and offers the kind of corrosion resistance you'd need in marine applications, and you don't mind a slightly higher price, then 5052 is your guy.

And for just general fabrication and structural use, 6061 is a solid choice. Just keep in mind that this grade of steel doesn't love to bend and isn't as easily formable as the other grades mentioned.

Don't leave empty handed
(or with the wrong material)

Our free Metal Buying Cheat Sheet for Fabricators is a quick-reference guide to common metal shapes, how they're measured, and what information you'll need before placing an order. It's a handy resource to keep on your phone or print for the shop.

Fill out the form to get your free copy!

What to look for in a SUPPLIER

So now that you've narrowed down what material, shape, size, and grade you need, how do you choose your supplier? Price is always top of mind, but another consideration should be offered services.

Ask not what you can do for your metal supplier, but what your metal supplier can do for you.... or whatever that classic expression is. If you don't have the truck to transport 20' or 40' sections, or the equipment to properly process it, then you should see if your metal supplier can help you make that material more manageable.

If paying a small fee can save you hours of labor in the shop, then letting them do the heavy lifting might be worth it. Many suppliers offer: saw cutting, shearing, plasma cutting, laser cutting, plate processing, tube rolling, material prep, and even custom parts production.

OUR TRUSTED RECOMMENDATIONS

While Earlbeck does not stock structural steel, plate, sheet, tubing, or really any metal that's not filler metal, we can point you in the direction of excellent metal suppliers in close proximity to our Maryland and Pennsylvania showrooms.

★ Metal Supermarkets Baltimore
7120 Golden Ring Rd
Baltimore, MD 21221

1. Earlbeck's Baltimore Showroom
8204 Pulaski Hwy
Baltimore, MD 21237
Get directions!

2. Earlbeck's Beltsville Showroom
10792 Tucker St
Beltsville, MD 20705
Get directions!

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★ Metal Supermarkets York
908 Roosevelt Ave
York, PA 17404

3. Earlbeck's York Showroom
95 Aberdeen Rd
York, PA 17406
Get directions!

4. Cristiano Welding Supply Showroom
An Earlbeck Gases & Technologies Company
4961 Birney Ave
Scranton, PA 18507
Get directions!

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Fronius Fortis: FREE Helmet, Backpack + Storage Bundle

7/1/2026

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If you've been eyeing a new Fronius Fortis, then now is the perfect time to commit and take advantage of this incredible offer! From July 1st, 2026, through August 31st, 2026, with your purchase of a new Fronius Fortis from Earlbeck, you'll score a FREE welding hood, backpack, and storage bundle valued at over $500!

WHAT MAKES THE Fronius FORTIS SO SPECIAL:

Compact machine design
Multi-process potential
Reliable and powerful
Intuitive operating system w/ Welding Parameter Wizard!
Easy connectivity: Wifi, Bluetooth, NFC optional
Durable rotary/push buttons that can be used even with gloves on, carrying handles, storage compartment, display protection, and perfect working height

Learn more about Fortis!

What's in the FREE Promo package:

This bundle offers a mix of safety protection and storage solutions that'll give you piece of mind and neat shop!

You'll receive a Fazor 1000 Plus Helmet, a Vizor Backpack, an OPT/s Welding Torch Holder, a Feed Roller Box with Foam, and a Wear Parts Box with Foam.

Total Value: $535

QUALIFYING MACHINE PACKAGES:

Already know exactly which Fortis package you want?
You can conveniently purchase your new machine through our online store!
Not certain which one best fits your needs?
Stop by one of our showrooms in MD or PA and our team will help you narrow it down!

BALTIMORE
8204 Pulaski Hwy
Baltimore, MD 21237

BELTSVILLE
10792 Tucker St
Beltsville, MD 20705

YORK
95 Aberdeen Rd
York, PA 17406

SCRANTON
4961 Birney Ave
Scranton, PA 18507

Fortis 270 Compact G - MIG Only Package
Meet the Fortis!
Fronius' newest series was crafted with small and medium-sized businesses in mind. The Fortis provides multi-process capabilities (MIG /TIG /Stick) with their superior welding tech, user-friendly operating system, and maximum connectivity!

ADD TO CART

Fortis 270 Compact G - Multiprocess Package (MIG/TIG/Stick)
Meet the Fortis!
Fronius' newest series was crafted with small and medium-sized businesses in mind. The Fortis provides multiprocess capabilities (MIG /TIG /Stick) with their superior welding tech, user-friendly operating system, and maximum connectivity!

ADD TO CART

Fortis 320 Compact G - MIG Only Package

Meet the Fortis!

Fronius' newest series was crafted with small and medium-sized businesses in mind. The Fortis provides multi-process capabilities (MIG /TIG /Stick) with their superior welding tech, user-friendly operating system, and maximum connectivity!

ADD TO CART

Fortis 320 Compact G - Multiprocess Package (MIG/TIG/Stick)

Meet the Fortis!

Fronius' newest series was crafted with small and medium-sized businesses in mind. The Fortis provides multiprocess capabilities (MIG /TIG /Stick) with their superior welding tech, user-friendly operating system, and maximum connectivity!

ADD TO CART

HOW TO CLAIM YOUR FREE PROMO PACKAGE

Purchase one of the listed qualifying Fortis packages from us before 8/31/26
Head over to Fronius' website and complete your warranty registration by 9/30/26
Congratulate yourself on your good choices and wait for your FREE gifts to arrive!

(49,0400,0151) Fortis 270 MIG, (49,0400,0152) Fortis 270 MIG/TIG/Stick, (49,0400,0153) Fortis 320 MIG, (49,0400,0154) Fortis 320 MIG/TIG/Stick 

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QUALIFYING Machines

Powermax45 SYNC– HandheldPowermax45 SYNC– Mechanized

Powermax65 SYNC– HandheldPowermax65 SYNC– Mechanized

Promotional Package Items (Pick 3 during claim process)

HOW TO REDEEM YOUR CONSUMABLES PACKAGE:

The RESULTS & BENEFITS

READY TO DITCH THE CYLINDERS?

Six Ways to Reduce the Stress of Piercing

Chain cutting

Edge Starting

Pre-Piercing

Double Piercing

Moving pierce

advanced piercing technology

HyPilot Cartridge

METAL SHAPES

FLAT BAR

SOLID STOCK

Angle IRON

SQUARE TUBING

Rectangle tubing

Round Tubing

PIPE

Sheet Metal

Metal Plate

MATERIAL GRADES

Carbon steel

Stainless steel

Aluminum

Don't leave empty handed (or with the wrong material)

What to look for in a SUPPLIER

OUR TRUSTED RECOMMENDATIONS

WHAT MAKES THE Fronius FORTIS SO SPECIAL:

What's in the FREE Promo package:

Total Value: $535

QUALIFYING MACHINE PACKAGES:

HOW TO CLAIM YOUR FREE PROMO PACKAGE

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Powermax45 SYNC– Handheld
Powermax45 SYNC– Mechanized

Powermax65 SYNC– Handheld
Powermax65 SYNC– Mechanized

Promotional Package Items
(Pick 3 during claim process)

Don't leave empty handed
(or with the wrong material)

STAY IN THE LOOP!
Subscribe to our monthly newsletter for welding tips, deals, and industry insights!