The Zapp Plus® vs the Everarc®: A Side-by-Side Comparison

Larin Dodgen
VP Engineering

I had the opportunity to weld with and deconstruct the Everarc, a welder offered by Everlinx. My team used the Everarc to complete roughly 200 welds and then I took it apart to see what was inside. As an engineer and having been involved in the design of the Zapp, Zapp Plus, Orion PJ, and Orion mPulse, I know my way around pulse arc welders. With the Zapp Plus being most similar to the Everarc, I did a side-by-side comparison. 

Power 

I was unable to find any information published by Everlinx to understand the Everarc's power range. That may have changed since I published this blog, but Everlinx is either hush-hush about the power range, they don't know the power range (which I doubt), or they don't care (which to me, an engineer, is out of the ordinary).

To better understand how the Zapp Plus compares to the Everarc I had to determine the power range myself. My testing revealed the Everarc has a power range of 0.5 to 15 joules (with the model made available to me). In comparison, the Zapp Plus has an expanded power range of 1 to 30 joules. The Zapp Plus has the power to do more than permanent jewelry, such as basic jewelry repair, whereas the Everarc does not have that capability.

Stylus 

The Zapp Plus is equipped with the Orion stylus, an “advanced stylus” design with a history of tens of millions of welds and constructed with solid metal components. The Everarc is equipped with a stylus that looks similar to the Orion stylus but with no significant performance history and constructed with mostly plastic components.

Detachable Stylus 

A detachable stylus is a plus for pop-ups. The Zapp Plus stylus will detach from the welder, allowing you to add an optional extension, providing as much as nine feet of stylus reach. The extension makes light work of anklets. You can also swap out your black Orion Stylus with a new stylus colors from Sunstone.

The Everarc stylus also detaches. 

Stylus Length 

The Zapp Plus stylus cord measures 72” in length from tip to tip. The Everarc stylus cord measures 63 inches from tip to tip. Stylus cord length becomes a critical issue when doing anklets. In this instance, it appears the Zapp Plus has an advantage over the Everarc in terms of length and being able to choose a different color of stylus. 

Power Selection 

The Zapp Plus uses a simple knob to select power. The Everarc uses two onion-skin buttons, a plus and negative, with the selected energy level displayed using LED components. Judging which is better, the knob or the onion-skin buttons, is preferential. However, here are some factual observations:

• When you turn on the Zapp Plus the selected energy is the same as when you turned the welder off. With the Everarc the energy level resets to four when you power off and then power on the welder.
• You must press the plus button repeatedly to select the desired energy level. For example, if you want to weld with 16 Joules, you must press the plus button 24 times.

Again, the knob versus the onion-skin buttons debate is preferential and there are pros and cons to each.

Quality Appearance 

The Zapp Plus is contained within a steel case with branding and control indicators silk screened to the top. (By the way, the pearl color you see on the top of the Zapp and the Zapp Plus were chosen by a group of permanent jewelry artists.) The Everarc is contained with a steel case with branding and control indicators placed on the front using a sticker. I wonder how well the sticker will withstand humidity and extreme temperature variations during shipping.

Circuitry

As an engineer, I was curious to see what components were used in the construction of the Everarc. As you might suspect, most electric components are sourced from China, so no surprises there. However, I wondered specifically about the choice of one component. Given the years I've been involved in pulse arc welder design, I would have chosen differently to avoid potential component failures six to ten months after purchase.

Warranty 

The Zapp Plus and the Everarc offer 3-year warranties. The Zapp Plus is eligible for Sunstone’s VIP customer service plan called the Sunstone Circle. In addition to many other program benefits, the Sunstone Circle offers a “lifetime warranty” for as long as you remain a member. Membership is only $15 per month for the Zapp Plus. When the warranty expires on the Everarc, the customer has no other recourse to protect their investment.

Lifetime Expectancy 

The Zapp Plus will continue to weld with satisfactory results long after the warranty expires. I can say that because I’ve been intimately involved in the designs of the the most proven welders for permanent jewelry in the world. Everything learned from building and reiterating for nearly a decade was in fact leveraged to build the Zapp Plus.

Everlinx does not appear to have any prior manufacturing experience with welders or any other electrical device or product. The company's About Us page does not mention any prior knowledge, expertise, or familiarity with the design, production, distribution, or delivery of customer support of a product like the Everarc. If that's true—Everlinx's lack of experience—then you shouldn't be surprised if the Everarc failure rate is high above normal thresholds. (I'm not saying it is as they're not likely to make that number public; however, based on the facts one can reasonable assume the failure rate is higher.)

Welding Performance 

Judging welding performance is subjective to one’s welding experience with different welders. I've welded with Zapp, Zapp Plus, all Orion models (the gold standard in permanent jewelry welders), PUK, the Helix the unbranded welder, and the Everarc. I found the Everarc welding performance unimpressive. 

Manufacturer Experience 

Perhaps a comparison of the two product boils down to this one silly—but factual—question: 

Would you purchase a welder from a company with months of micro welding experience or from a company with nearly 20 years of micro welding experience? 

Factually, the Everarc is represented by a company with little to any welding technology knowledge. I also wonder how well the Everarc team will be able to provide customer assistance with the limited knowledge their customer service team possesses.

I realize I keep coming back to expertise, but it’s important. 

It’s Not Just About the Welder 

In the end, a factual comparison may do nothing more than create additional confusion. Allow me to pose four suggestions that look beyond the welder: 

Your financial plan, expertise level, and business insight are all critical factors in your decision-making process. In a world where one size does not fit all, don't align yourself with a company that limits you to a single welder option.

2. Choose a Partner that has Your Back

Murphy’s Law dictates that mishaps will occur at the worst possible moments. While you can't prevent unforeseen issues, you can select a PJ welder manufacturer that provides robust support when needed most. Opt for a partner that's prepared to offer assistance whenever challenges arise.

3. Choose a Partner that’s Working to Build the Industry

The Permanent Jewelry Expo (PJX) is the only meeting of its kind with a mission to promote permanent jewelry and raise the tide for everyone. MicroWeld is a more intimate, hands-on meeting and the only jewelry welding conference in the world. Both conferences, organized by Sunstone, provide much-needed education and networking for the industry. Sunstone also created a 17-step permanent jewelry training video series that’s free to everyone. Can you think of any other company so dedicated to building the permanent jewelry industry?

4. Choose a Partner You can Trust

Why do the most respected jewelry suppliers in the world carry Sunstone welders? Suppliers take great care in choosing what products they offer to their customers. Product quality, expertise, knowledge, track record, and service are key in building and maintaining relationships of trust. Your permanent jewelry business will do well when you seek out a company that is interested in your success more than their success. 

Picking the right partner is no less important than choosing the right welder. Sunstone is here to help. Call or text us at 385-999-5214 and let us answer your questions. 

Sunstone, Orion, and Zapp Plus are registered trademarks and Zapp, Orion PJ, and Orion mPulse are trademarks of Sunstone Engineering LLC. Helix is a trademark or registered trademark of its respective manufacturer. 

This article was updated August 1, 2024