Hypertherm SmartSYNC Cartridge 85 A — FlushCut™ The FlushCut™ cartridge solves one of the most common field challenges in fabrication and marine work: removing welded-on attachments, lugs, pad eyes, and positive features as close to the base plate as possible — without piercing or damaging the underlying surface. The recessed nozzle geometry angles the plasma arc to cut right at the base, eliminating the need for secondary grinding in most applications. Key Specifications Cartridge Type - FlushCut™ Operating Range- 25–85 A Base Damage - None Workpiece protected Torch Interface - SmartSYNC®Only — no adapter option Systems - PM85 / PM105SYNC® only Post-Cut Finish - Near-FlushMinimal grinding required Product Highlights Cuts flush to the base plate— recessed nozzle design angles the arc to sever attachments at their base without gouging into the parent material No workpiece piercing or damage— the defining advantage of FlushCut™ technology; the arc terminates at the surface, not through it Eliminates or drastically reduces secondary grinding— the near-flush cut result means far less post-cut cleanup compared to standard cutting or grinding methods 25–85 A operating range— wide amperage window allows the operator to fine-tune output for different attachment sizes and base material thicknesses Suited to a wide range of attachment types— lugs, pad eyes, lifting eyes, cleats, studs, brackets, and any other positive feature welded to a plate or structural member SmartSYNC® integration— automatic process recognition and configuration when used with Powermax85/105 SYNC® systems Single-piece cartridge— all consumable components integrated; no loose nozzle, electrode, or shield to manage during changeover Genuine Hypertherm OEM— engineered and manufactured to Hypertherm's exacting tolerances for reliable, repeatable FlushCut performance Ideal Applications Marine & Shipbuilding - Remove pad eyes, cleats, and lifting lugs from hull plates and structural members during ship repair or decommissioning without damaging the hull. Structural Steel & Fabrication - Clean removal of temporary lifting lugs, construction attachments, and erection aids from structural members after installation is complete. Maintenance & Repair - Remove worn or damaged attachment points from equipment, frames, and pressure vessels where base metal integrity must be preserved. Heavy Equipment & Industrial - Strip welded-on brackets, hooks, and fixtures from heavy equipment frames during refurbishment or design modification work. SmartSYNC® Torch Required — No Duramax® Adapter Option Unlike other Hypertherm SYNC cartridges, the FlushCut™ #428953 is only compatible with SmartSYNC® torches on Powermax85 SYNC® and Powermax105 SYNC® systems. There is no cartridge torch adapter available for this cartridge — it cannot be used with Duramax® torches or non-SYNC Powermax systems. If you're unsure which torch you have, contact the QWS team before ordering. System Compatibility System Torch Interface Compatible Powermax85 SYNC® SmartSYNC® hand torch Direct cartridgePrimary Yes Powermax105 SYNC® SmartSYNC® hand torch Direct cartridgePrimary Yes Powermax45 SYNC® / XP — — Not compatible Powermax65 SYNC® — — Not compatible Powermax85 / 105 (Duramax® torch) Duramax® torch No adapter available No adapter option Need a different specialist cartridge? If you're after fine detail cutting on thin material, see the FineCut Cartridge #428928. For general cutting up to 16 mm, the 45 A Drag Cutting Cartridge #428927 is the everyday workhorse. The QWS team can help confirm the right cartridge for your application and system — get in touch.
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