Open the HPR® XD consumable listings and you'll find them split three ways: mild steel, stainless, aluminium. Three sets of cut charts, three sets of pages.
Which leads a lot of shops to assume they need three separate inventories.
They don't. Most of those are the same physical part shown on a different page.
What we stock for these torches
Thermacut® direct-replacement consumables, compatible with Hypertherm® HPR® XD torches. Shields, shield caps, inner retaining caps, nozzles, swirl rings and electrodes — every one listed against the OEM number it crosses to, so you can check the fit yourself before you order.
Thermacut® is an independent manufacturer. The Hypertherm® and HPR® names identify what the parts fit.
What's shared across materials
Our Thermacut® range for these torches runs to 87 unique parts covering all three materials. Not 87 per material — 87 in total.
That's because the material doesn't change most of the hardware. It changes the process — the gas, the amperage, the settings — and the process selects which of the existing parts you assemble. A shield that works at 200 amps on stainless is the same shield at 200 amps on mild steel.
Practical consequence: a shop cutting two materials is usually stocking far fewer distinct parts than the page structure suggests. Worth knowing before you build a min-max on a spreadsheet.
What genuinely changes
Amperage does most of the work. The range runs from 45 amps up through 130, 200, 260 and 400. That's the axis that actually changes your parts, and it's the one to get right first.
Some material-specific parts do exist, and they're real — not a marketing split. Where Hypertherm's® published cut charts specify a different part for a material at a given amperage, we follow the chart rather than the convenience of a shared listing.
And at 400 amps on mild steel, three parts change again. That stack uses the heavy-duty versions of the shield cap, the shield and the inner retaining cap. Stainless and aluminium at the same 400 amps stay on the standard parts.
That HD distinction is exactly what gets missed when somebody cross-references by OEM number alone — the heavy-duty part carries the same base OEM number with a suffix. Same number, different part, different job.
The mistake that costs the most
Cross-referencing by OEM number and stopping there.
An aftermarket part can cover a narrower amperage range than the OEM part it crosses to. The number matches, the part arrives, and it's rated for a range that doesn't include the amperage you actually run.
The fix is boring and it works: check the amperage range on the aftermarket part against your stack, every time. Hypertherm's® cut charts are the authority on what your stack should be. A catalogue label on a cross-referenced part is a starting point, not a confirmation.
We run that check on every stack in our finder — amperage and gas, against the cut chart, part by part. That's the work you're not doing when you use it.
Pack quantities
Several of these consumables ship as five-packs — electrodes and some nozzles especially.
It matters more here than on an air plasma machine because the parts cost more to begin with. A five-pack price next to a single-part price is not a comparison, and if you're building a budget off a parts list, check every line.
Our titles carry the pack quantity and the finder shows it on the stack row.
Let the finder assemble it
Pick your material, pick your amperage, and the finder returns the complete stack in torch assembly order — with the Hypertherm® number each Thermacut® part crosses to, and the pack sizes shown.
It's free and it doesn't require an account.
TorchandTip.com sells Thermacut® aftermarket plasma and welding consumables across Canada. Thermacut® is an independent manufacturer. TorchandTip.com is not affiliated with, authorized by, or endorsed by Hypertherm®, ESAB®, Lincoln Electric®, Kjellberg®, or any other original equipment manufacturer. All OEM names, model numbers, and part numbers are used for identification and reference purposes only.
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