If you're still outsourcing plasma cutting, you're literally watching your profit margins drive away in someone else's truck.
Here's what most job shop owners don't realize: Every time you send parts out for cutting, you're not just paying for the service – you're paying for their overhead, their profit margin, their equipment financing, AND you're losing 3-7 days of turnaround time that could have been billable hours.10
The math is brutal. And it's costing you more than you think.
Let's break down the real numbers – and show you exactly how a StarLab CNC plasma table can transform your shop from margin-squeezed to profit-focused in less than a year.
The Hidden Costs of Outsourcing Plasma Cutting (That Nobody Talks About)
Beyond the Invoice: What Outsourcing Really Costs Your Shop
Most fabricators look at the per-part cost and think they're getting a deal. But here's what that invoice doesn't show:
- Lead Time Delays: 3-7 day turnaround means you can't take rush jobs or quick-turn projects that command premium pricing
- Quality Control Issues: Wrong dimensions? Material mix-ups? Now you're waiting another week for replacements
- Minimum Order Requirements: Forced to overbuy materials or wait until you have enough parts to meet minimums
- Lost Design Flexibility: Can't iterate quickly or make last-minute customer changes without blowing budgets
- Profit Margin Erosion: That 40% markup on outsourced cutting eats directly into your bottom line
Real Results from Fab Shops:
"After we brought cutting in-house with our StarLab table, our per-part cost dropped significantly. We went from 15-day lead times to same-day turnaround. We're now taking jobs we used to turn away because of outsourcing bottlenecks."
– Job Shop Owner, Midwest
The In-House Advantage: Why Job Shops Are Making the Switch
1. Dramatic Cost Savings (60-70% Per Part)
Let's look at a real-world comparison for a typical job shop cutting 200 parts per month:
Outsourced vs. In-House: Cost Analysis
Industry studies show that bringing plasma cutting in-house typically reduces per-part costs by 60-70% compared to outsourcing.
Your actual savings depend on several factors:
- Current outsourcing volume: Higher volume = faster ROI
- Part complexity: Simple parts show the most dramatic savings
- Turnaround requirements: Rush fees from suppliers add up quickly
- Shipping costs: Eliminated entirely with in-house cutting
- Material waste: Efficient nesting reduces scrap costs
What does this mean for your shop? If you're currently outsourcing cutting work, track your actual monthly costs (including shipping, delays, and rework) and compare that to the operating costs of in-house cutting: consumables, electricity, and equipment payments.
With StarLab's equipment financing options, your monthly payment is typically less than what you're currently spending on outsourcing. You're literally replacing an expense with an asset that pays for itself.
2. Lightning-Fast Turnaround = More Jobs, Higher Margins
Here's where in-house cutting becomes a profit multiplier:
- Same-Day Turnaround: Design in the morning, cut by afternoon, weld tomorrow. Take rush jobs that command 25-40% premium pricing.
- Rapid Iteration: Customer wants a design change? Make it in 20 minutes, not 2 weeks.
- Increased Capacity: Don't turn away work because of outsourcing bottlenecks. Cut what you need, when you need it.
- Competitive Advantage: Quote faster, deliver faster, win more bids.
Fabrication Shop Success Story:
"Before our StarLab table, we'd lose a significant percentage of rush jobs because we couldn't promise quick turnaround. Now we're the go-to shop for emergency work. Those rush jobs alone generate substantial additional revenue each month at premium pricing. The table paid for itself faster than we expected."
– Fabrication Shop Owner, Texas
3. Built for Daily Production – Industrial Reliability You Can Count On
Job shops can't afford downtime. That's why StarLab tables are engineered for continuous production:
- Heavy-Duty Frame Construction: Welded steel frame handles daily production without flex or drift
- Industrial Linear Guides: Precision components rated for millions of cycles
- Professional Control Systems: Linux-based CommandCNC – stable, reliable, no crashes
- Minimal Maintenance Required: Simple daily checks keep you cutting, not wrenching
- Proven Track Record: Hundreds of shops running 8-10+ hours daily with 99%+ uptime
Translation: Your StarLab table will be ready when your jobs arrive. No "the machine is down" excuses to customers.
Your Custom ROI: Will a StarLab Table Pay for Itself in Your Shop?
Every shop is different. Let's calculate YOUR potential return on investment:
Calculate Your Potential ROI:
To determine if in-house cutting makes sense for your shop, gather these numbers:
- Current monthly outsourcing cost: Include parts + shipping + rush fees + rework
- Estimated in-house operating cost: Consumables + electricity + maintenance (typically 30-40% of outsourcing cost)
- Monthly savings potential: The difference between outsourcing and operating costs
- Equipment investment: Table cost + installation + training
- Payback period: Equipment investment ÷ monthly savings
Additional Revenue Opportunities (Often Overlooked):
- Take on cutting jobs for other shops: Many StarLab owners generate additional revenue doing contract cutting for local fabricators
- Expand your service offerings: Add plasma cutting to your capabilities list, attract new customers
- Premium pricing for quick turnaround: Charge more because you can deliver faster than competitors who outsource
- Reduce material waste: Efficient nesting software maximizes every sheet, reducing scrap costs
Common Concerns (And Why They Shouldn't Stop You)
Objection #1: "The Upfront Cost Seems High"
Reality Check: You're already paying for a CNC plasma table – it just belongs to your supplier, not you.
- With financing, monthly payments typically run $800-1,500 depending on table size
- Most shops save more than the payment amount in the first month
- After payoff (typically 3-5 years), you own an asset that continues saving you thousands monthly
- Tax benefits: Section 179 allows you to deduct the full purchase price in year one
Bottom Line: The question isn't "Can we afford it?" – it's "Can we afford NOT to own our cutting capacity?"
Objection #2: "We Don't Have Space for a Plasma Table"
Reality Check: StarLab tables are surprisingly compact for their cutting capacity.
- 4'x4' table footprint: ~8' x 8' total space including clearances
- 4'x8' table footprint: ~8' x 12' total space
- Many shops fit them in spaces currently used for material storage or dead floor space
- Wall-mounted computers and minimal auxiliary equipment needs
Pro Tip: Calculate the square footage cost vs. the monthly savings. Even prime shop floor space pays for itself quickly.
Objection #3: "We Don't Know How to Run CNC Equipment"
Reality Check: Modern CNC plasma is easier than you think – and we ensure you succeed.
- Complete Training Included: We teach you everything from design to finished part
- Intuitive Software: SheetCam TNG is specifically designed for fabricators, not engineers
- Learning Curve: Most operators are cutting quality parts within 2-3 days
- Ongoing Support: Phone and email support included – we're here when you need us
- Pre-Loaded Settings: Cutting parameters for common materials already programmed
Real Talk: If you can run a plasma torch by hand, you can run a StarLab table. The software does the hard part.
Objection #4: "What About Maintenance and Consumables?"
Reality Check: Maintenance is minimal, and consumable costs are predictable.
- Daily maintenance: 5-10 minutes (check consumables, clean table)
- Weekly maintenance: 15 minutes (lubrication, check connections)
- Consumables: Budget $50-150/month depending on cutting volume
- Major service: Annually (similar to any production equipment)
Compare This To: The uncertainty and delays of outsourcing. You control your schedule and costs.
Why Fabricators Choose StarLab CNC
Purpose-Built for Job Shop Environments
Professional Control Systems
Linux-based CommandCNC or CandCNC EtherCut systems – no crashes, no freezes, just reliable daily operation. These aren't hobby controllers; they're industrial control systems trusted by production shops.
True Industrial Construction
Heavy-duty welded steel frame, precision linear guides, quality stepper motors. This is equipment built to run 8-10 hours daily, not 2 hours weekly. You'll pass this table on to the next generation of your business.
Advanced Torch Height Control
Automatic THC maintains perfect cut height on warped or uneven material. No manual height adjustments, no gouged parts, no wasted material. Cut it right the first time, every time.
Flexible Table Sizes
From 4'x4' (perfect for smaller shops or specific work), all the way to 10'x40'. Choose the size that matches your typical work – then handle the exceptions when they come up.
Designed for Real Materials
Cut mild steel up to 1" thick, stainless to 1/2", aluminum to 3/4". Handle the full range of work that comes through your shop door without limitations.
Integration-Ready
Works with your existing plasma cutter (Hypertherm, Miller, Lincoln, etc.). No need to replace equipment that's still working – just add the automation that multiplies your capacity.
From Drawing to Finished Part in Hours, Not Days
Here's your new workflow with a StarLab CNC table:
- 9:00 AM – Customer Calls with Rush Job
"Can you cut 50 brackets by end of week?" (You think: I can have them done by tomorrow morning.)
- 9:30 AM – Import or Create Design
Import their DXF file or quickly draw it in CAD. Either way, you're ready to cut in minutes.
- 10:00 AM – Generate Toolpath in SheetCam
Load the design, select material type, nest the parts efficiently. SheetCam optimizes everything automatically. Five minutes of setup, then generate G-code.
- 10:15 AM – Load Material and Start Cutting
Put your sheet on the table, run the program, walk away. The table and THC handle everything while you work on the next job.
- 11:30 AM – 50 Parts Cut and Ready
Parts are cut, edges are clean, dimensions are perfect. Start welding or move to the next process. Customer gets parts tomorrow instead of next week.
That's the power of in-house cutting. You control the timeline. You control the quality. You control the profit.
Fabricators Who Made the Switch (Real Results, Real Shops)
Case Study: Agricultural Equipment Fabricator
Challenge: Significant backlog due to outsourcing bottleneck, turning away work regularly
Solution: 5'x10' StarLab table with Hypertherm plasma system
Results After 6 Months:
- Eliminated backlog completely
- Substantially increased monthly revenue capacity
- Hired additional welders to handle increased throughput
- Table ROI achieved faster than projected
- Now doing contract cutting for other local shops
Case Study: Custom Trailer Manufacturer
Challenge: Every trailer required outsourced parts with 7-10 day lead times impacting sales
Solution: 4'x8' StarLab table with equipment financing
Results After 1 Year:
- Reduced time-to-delivery from 3 weeks to under 1 week
- Significantly reduced per-trailer production costs
- Monthly equipment payment offset by operational savings
- Gained ability to customize designs quickly for customer requests
- Added precision-cut custom parts as premium option
Case Study: Structural Steel Fabricator
Challenge: Plate cutting was the primary bottleneck in project timelines
Solution: 5'x10' StarLab table with water table for thick plate cutting
Results After 9 Months:
- Eliminated monthly outsourcing costs entirely
- Reduced overall job cycle time significantly
- Brought plate work in-house that was previously subcontracted
- Equipment payment covered by cost savings with margin to spare
- Added contract cutting services for other steel contractors
StarLab vs. Other Options: Why Fabricators Choose Us
| Factor | Cheap Import Tables | Big Name Brands | StarLab CNC |
|---|---|---|---|
| Price Point | Budget range | Premium range | Mid-range professional |
| Build Quality | Light duty, frequent issues | Excellent, over-built | Industrial grade, right-sized |
| Support | Email only, overseas | Good but expensive | US-based, included |
| Software | Basic/outdated | Proprietary, expensive | Professional, industry-standard |
| Daily Production Ready | ❌ 2-4 hours/day max | ✓ But overkill for most shops | ✓ Perfect for 12+ hour days |
| ROI Timeline | Questionable (downtime, rework) | Longer payback period | Competitive ROI for job shops |
| Best For | Hobbyists, light use | Large production facilities | Job shops & fabricators |
The Sweet Spot: StarLab gives you industrial reliability and performance at a price point that makes sense for job shops. You're not overpaying for capacity you don't need, and you're not buying cheap equipment that won't survive daily production.
Stop Sending Your Profit Margins Out the Door
Every day you outsource plasma cutting is another day you're:
- Paying 60-70% more per part than necessary
- Turning away rush jobs you could have taken
- Watching competitors who own their cutting capacity steal your customers
- Building someone else's business instead of your own
The shops making money in fabrication right now aren't the ones with the best welders or the biggest facility – they're the ones who control their entire production process.
Your competitors are either already cutting in-house, or they're looking at this same decision right now. The question is: Do you want to be ahead of them or behind them?