Hobart Plasma Cutter 40i Review
Last updated ago
4 min read
Welding Buddy Experts
August 17, 2021

Hobart Plasma Cutter 40i Review

Last updated ago
4 min read
Welding Buddy Experts
August 17, 2021

The Airforce 40i is Hobart's most expensive and efficient plasma cutting line. With a combination of fast cutting speed, excellent capacity, solid duty cycle, and compact durability, the 40i makes a perfect choice for anyone who wants a plasma cutter for domestic to light industrial use. Hobart is a well-known brand among welders, known for its high-power, high-quality, and moderately priced products. They've diversified into the plasma cutter business, and their heritage remains as strong as ever.

With its many efficiencies and safety features, this dependable machine is excellent for those looking for a high-performing plasma cutter to use in their garage or workshops. Before you go looking for a Hobart 40i plasma cutter for sale, this review will equip you with all the information you'll need to make the right decision.

Who should get the Hobart Airforce 40i plasma cutter?

This machine is a high-quality plasma cutter. The Hobart Airforce 40i is more suitable for advanced metal work than the Hobart Airforce 12ci and Hobart 27i. If you're looking to work in fabrication, light construction, HVAC, autobody, farm/ranch, sheet metal, or plumbing applications, the Hobart 500576 airforce 40i plasma cutter is mighty capable.

The Airforce 40i can quickly cut through a wide range of conductive metals and thicknesses. The Hobart 40i plasma cutter is known for its versatility in cutting efficiency. The Airforce 40i plasma cutting kit, which includes an XT40R portable torch, XT consumables, and a high-duty work clamp with wire, is ideal for both light and heavy industrial applications. Because of its inverter configuration, the machine is lightweight and compact. Not only that, the Hobart Airforce 40i has a smoother and more blunt cut with less slag and a thinner kerf than Oxy-Fuel cutters. You won't have to worry about flame tuning, gas pressure settings, or metal preheating.

Its portability is also important. If you are a busy mechanic who has to drive a lot, the compact and lightweight designs are very appealing. It also uses consumables more efficiently, saving you more money.


  • Exceptional cutting results
  • Capable of severing extended metal, polished, or painted surfaces
  • Produces a more accurate cut with less slag
  • Setup is easy.
  • Ergonomic and easy to use
  • The pressure setting is automatically adjusted.
  • Design with a single knob
  • Fast, simple, and clean
  • Hobart's exceptional 5/3/1 warranty
  • The onboard diagnostic system allows you to see what's wrong with your device at a glance.
  • Dimensions are compact and lightweight.
  • Easy to understand Hobart 40i plasma cutter manual


  • The ground clamp is a bit flimsy but easy to move around.
  • Some users would've preferred a longer power cord.
  •  A bit expensive

Hobart Plasma Cutter 40i Main Features and Benefit

Powerful and Fast Cutting Performance

Whatever the metal form or thickness, the Hobart 40i cuts it rapidly, reliably, and precisely. With clean cuts up to 3/8 inch aluminum, 5/8 inch steel, 3/16 inch bronze, 3/8 inch stainless, 3/8 inch galvanized, and 14-inch brass, the 40i is up for any job. It can cut mild steel at a rate of 52 inches per minute on quarter-inch steel, making it extremely powerful.

Lightweight and Compact Design

Another excellent attribute of this cutter is its lightweight and compact build. It's not as heavy compared to most plasma cutters (only 34 lbs) due, in part, to its inverter design. Furthermore, the machine's weight doesn't negatively impact its efficiency.

Minimal Electrical Consumption

The Airforce 40i's power factor correction (PFC) circuitry enables the unit to consume less than 30% amperage for the same cutting work as its nearest competitor. It also helps users extend their work area with an extension cord while reducing irritating circuit breaker trips caused by voltage variations.

Ergonomic XT40R Torch

The Hobart 40i also has an XT40R torch. This variant has an ergonomic nature that eliminates fatigue and makes for longer work hours. The handle feels relaxed and at ease in the user's palm.

Post-Flow Cooling System

The post-flow cooling system is integral to cooling down the 40i plasma cutter efficiently after the machine is shut down. This process helps keep the unit at an optimal temperature, preserving the life span of its consumables, such as torch tips and electrodes.


This model includes Hobart's fan-on-demand innovation. It protects the device by preventing the entry of debris and dust into the internal chamber of the cutter, thus protecting the internal components from injury. Furthermore, the fan can only run when required, resulting in additional power savings.

Wind Tunnel Technology

Wind tunnel technology is vital for protecting the Hobart 40i's PC board and other electric components from potential contaminants such as debris, dust, or dirt.

Compatible with Engine Driven Welders

When electric power is not required for arc welding, engine-driven welders are commonly used. These are typically used for outdoor welding. You can attach the Airforce 40i to a 240v 8KW generator-powered engine-based welding machine to increase its cutting performance. This will grant you up to 3/8 to 5/8 inch thick mild steel welds.

Thermal Overload Protection

The thermal overload security option on the Hobart Airforce 40i is handy. It keeps the machine from being phased during cutting through any operating conditions. As a result, if the airflow is interrupted or the duty cycle exceeds its cap, the terminal overload safety will activate, and the system will shut down automatically. This safeguards it against further damage.

The 5/3/1 Hobart Warranty

The Airforce 40i, like its predecessors, comes with a 5-year warranty on stabilizers, transformers, and rectifiers, a 3-year warranty on PC boards, generators, and drive systems, and a 1-year warranty on Plasma cutters, MIG, and TIG torches.

Technical Specifications

  • Input voltages: 240V
  • Output current: 40A
  • Duty cycle: @ 40° C (104° F) CSA
    • 50% at 40 amps
  • Dimensions with handles: 17 x 18.2 x 11.6 in.
  • Weight: 34.3 pounds
  • Rated cut: 5/8-inch mild steel
  • Sever cut: 7/8-inch steel.
  • Recommended airflow: 4.8 CFM at 90-120 PSI

Inclusions: XT40R torch, 10 ft. power cord, 12 ft. clamp cable, Hobart 40i plasma cutter consumables


Overall, the Hobart 40i is one of the most delicate plasma cutters available in its price range. Hobart has truly outdone itself by entering the plasma cutter market. They continue to have an outstanding warranty and excellent performance for their products. In terms of cost, their plasma cutter is comparable to other brands.

You might also like
Inspiring and educating the current and next generation of welders.

Subscribe to our newsletter

Be first to know about specials! Our newsletter will keep you up to date on everything welding. Join our mailing list.