I suspect there is some sort of manufacturing defect within the torch assembly....assuming you purchased the unit from a dealer....you can go back and get them to replace the whole torch assembly under warranty....if you purchased it via internet...you should go back to the internet company that sold it to you for warranty coverage....this often is a little more time consuming.
You can contact Hypertherm tech service for advice....have your machine serial number handy. Here is the contact info:
Technical Service
technical.service@hypertherm.com
800-643-9878 Tel - Toll Free in USA
and Canada Customer Service
customer.service@hypertherm.com
800-737-2978 Tel - Toll Free in USA
and Canada
Return Materials
return.materials@hypertherm.com
866-643-7711 Tel - Toll Free in USA and Canada
Best regards....sorry for the issue. I will forward your post to Hypertherm tech service.
Jim Colt