Hobart Airforce 40i Plasma Cutter Review

Hobart Airforce 40i Review

Versatile and Powerful Performance

Brand Name - Hobart

Designed For - Light and heavy industrial uses



User Review


If you want both the versatility and powerful performance from a plasma cutter, Hobart 500566 Airforce 40i Plasma Cutter is the unit that can meet your cutting needs.

Airforce 40i easily slices through a wide variety of conductive metals and thickness. Versatility in the cutting performance is the specialty of Hobart 40i plasma cutter.

Featuring with an XT40R handheld torch, XT consumables, heavy-duty work clamp with cable, the Airforce 40i plasma cutting system is excellent for light as well as heavy industrial uses.

Its inverter design makes the unit lightweight, portable as well. Not only that, Hobart airforce 40i offers you a faster and more precise cut with less slag and thinner kerf than cutting with Oxy fuel.

You don’t need to be worried about flame tuning, gas pressure setting or metal preheating.

Let’s have a look all of its great features that make Hobart 500566 Airforce 40i Plasma Cutter best.

Cutting Capacity

No matter what types or what is the thickness of the metal, Hobart 40i just cut it quickly, easily as well as precisely. The unit offers you clean cut up to 5/8 inch steel, 3/16 inch copper, 3/8 inch aluminum, 3/8 inch stainless, ¼ inch brass and 3/8 inch galvanized.

Lightweight and Portable

Hobart 40i offers robust performance at half the weight. Integrated with inverter design, this cutting unit weighs only half of what others standard plasma cutter weigh without compromising its cutting performance. This feature also makes the unit portable and you won’t face any difficulties to move it from one work site to another work site.

Ergonomic Design XT40R Torch

Hobart 40i comes with an XT40R torch. Its ergonomic design makes it very comfortable in the operator’s hand. You won’t feel any fatigue even after working with it for a long time.

Engine-Driven Welders Compatibility

This plasma cutter is compatible with the engine- driven welders. You can increase its cutting capabilities by hooking it to an engine-driven welder with a 240V generator power outlet of 8KW or more. In this set-up, you can cut 3/8 to 5/8 inch mild steel.

Airforce 40i Fan-on-Demand Technology

This unit is integrated with the fan-on-demand technology. The fan runs only when needed. Thus, it decreases the overall power consumption. While the unit is on running, it also limits the amount of airborne debris and dust entering into the unit. In this way, the fan saves the inner part of the machine from being damaged.

Wind Tunnel Technology

Featuring with wind tunnel technology, this unit draws internal air flow. As a result, the PC board and other internal components remain protected from noxious external dust, dirt, and debris.

Airforce 40i Thermal Overload Protection

This feature allows Hobart 40i to remain unaffected even in tough working conditions. If accidentally the air flow blocked or the duty cycle crossed the limit, the thermal overload protection helps the unit to automatically shut down and thus prevent machine damage.

Post-Flow Cooling System

Hobart 40i features the post-flow cooling system. As a plasma cutter operator, you know that the standard units stay hot for a while, even after finishing the cutting job. But the post-flow cooling system of Hobart 40i helps it to cool quickly just after your cut. Thus, it helps the tips and electrodes to extend the life.

Hobart Airforce 40i Product Specifications

Product Dimensions

17 x 18.2 x 11.6 inches

Product Weight

34.3 lbs

Duty Cycle

50% at 40A

Cut Performance

Clean cut 5/8 inch (mild steel)

Sever cut 7/8 inch (mild steel)

Input power


Plasma Gas Pressure/ Flow

4.8cfm at 90 to 120PSI

What's Included

  • Torch - XT40R
  • Clamp cable - 12ft. length
  • Power cord - 10ft. length
  • Consumables

Hobart Airforce 40i Applications

  • Light construction
  • Fabrication
  • Auto body
  • HVAC
  • Sheet Metal
  • Plumbing
  • Farm/Ranch


  • Lightweight and portable
  • Powerful cutting performance
  • Able to cut expanded metal, coated or painted surfaces
  • Provide precise cut and produce less slag
  • Easy to set up
  • Comfortable cutting torch
  • No flame tuning or pressure setting is needed
  • Single knob design
  • Quick, easy and clean cutting process


  • Nothing found


Q. Does the working piece need any preheating?

A. No, the metal doesn’t need heating prior to cutting

Q. Is the unit suitable to cut rusty and painted materials?

A. Obviously, it can cut painted and rusty materials. But you’ll need a clean ground.

Q. Does the unit need any pressure setting prior to cutting?

A. Not at all. No flame tuning or gas pressure setting is required.

Q. Will it work at 30 amp 220V circuits?

A. Yes, the 40i system will work with
Input Voltage: 220/230/240 V
Input Phase: 1-phase
Amperage: 20 - 40 A

Hobart Airforce 40i User’s Feedback

The user’s feedback on this unit is great. No negative comments still found. The users are satisfied with its great cutting performance. The streams of the happy user just called the unit “awesome”. One of the users commented, “Hobart 40i works great on a lot of smaller detail works like making Plasma Art, signs and Garden Art”.

Each and every user wish to recommend Hobart airforce 40i who is searching for a versatile, high- quality as well as an economical plasma cutter.

Concluding Decision

Hobart 500566 Airforce 40i Plasma Cutter is the best possible unit for you if you want a lot of performance in a very economical package. If you’re not a regular user of the plasma cutter, the price seems to you a little high, but this is a perfect unit for them who need to do a lot of cutting jobs.

Definitely, it can be a great addition to your work site.
Ronald Wilson

I’m Ronald, Specialist engaged in the manufacture of fabricated metal products. I’ve been involved in the fabrication industry since 1998. To continue my love in welding and to share my experience I've formed a research team and have created this website for our valuable customers.

Click Here to Leave a Comment Below 2 comments