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The analysis of the influence of various design solutions of the gas-dynamic stabilization system in plasma torches for cutting metals on the efficiency of equalizing the velocities of gas flows along the cross-section of the gas path is carried out. It is noted that the efficiency evaluation method developed by the authors should be based on the calculation of the uniformity of the gas flow velocity distribution over the cross-section of the gas-air path of the plasma torch. A vortex stabilization system using two swirlers is proposed. The effect of improving the reliability and quality of plasma cutting is shown. The results of the efficiency studies for the proposed system of gas-vortex stabilization in metal-cutting plasma torches are presented. The calculating results of equalization coefficients for the velocity distribution in different parts of the gas-dynamic stabilization system in the plasma torch are presented. Based on the results of the calculations, a constructive optimization of the gas-air path in the plasma torch was performed. The experimentally obtained advantages of the new upgraded plasma torch in terms of the gas-vortex stabilization efficiency are demonstrated. The effects of improved cutting quality and reduced nozzle wear in the new plasma torch are shown. This is due to the higher degree of the plasma arc stabilization in the new plasma torch, which leads to a decrease in its oscillations, and, consequently, to an increase in the efficiency of the cutting process. © 2021 Institute of Physics Publishing. All rights reserved.