An electrode for a plasma cutting system, the electrode comprising: an arc portion shaped to matingly engage a nozzle of the plasma cutting system, the arc portion having a first end comprising a plasma arc emitter disposed at a distal end thereof; and a thermal portion in thermal communication with a second end of the arc portion, the thermal portion shaped to slidingly engage a complementary swirl ring (206,306) of the plasma cutting system and including: (i) a first circumferentially formed disk-shaped flange mating feature extending radially from a proximal end of the thermal portion of the electrode, the first circumferentially formed disk shaped flange mating feature defining a first radial width to interface with the swirl ring said first disk-shaped flange mating feature including a sealing member configured to form a dynamic seal with the swirl ring so to limit a flow of a gas from a forward side to a rearward side of said first disk-shaped flange mating feature, (ii) a second circumferentially formed disk-shaped flange mating feature extending radially from a distal end of the thermal portion of the electrode to define a second radial width to interface with the swirl ring, and (iii) a thermal exchange surface region defined by a generally cylindrical portion of the thermal portion between the first disk-shaped flange mating feature and the second disk-shaped flange mating feature, the thermal exchange surface region defining a set of annular flanges extending from the thermal portion between the first circumferentially formed disk-shaped flange mating feature and the second circumferentially formed disk-shaped flange mating feature, the set of annular flanges having a radial width less than at least one of the first radial width and the second radial width. an arc portion shaped to matingly engage a nozzle of the plasma cutting system, the arc portion having a first end comprising a plasma arc emitter disposed at a distal end thereof; and a thermal portion in thermal communication with a second end of the arc portion, the thermal portion shaped to slidingly engage a complementary swirl ring (206,306) of the plasma cutting system and including: (i) a first circumferentially formed disk-shaped flange mating feature extending radially from a proximal end of the thermal portion of the electrode, the first circumferentially formed disk shaped flange mating feature defining a first radial width to interface with the swirl ring said first disk-shaped flange mating feature including a sealing member configured to form a dynamic seal with the swirl ring so to limit a flow of a gas from a forward side to a rearward side of said first disk-shaped flange mating feature, (ii) a second circumferentially formed disk-shaped flange mating feature extending radially from a distal end of the thermal portion of the electrode to define a second radial width to interface with the swirl ring, and (iii) a thermal exchange surface region defined by a generally cylindrical portion of the thermal portion between the first disk-shaped flange mating feature and the second disk-shaped flange mating feature, the thermal exchange surface region defining a set of annular flanges extending from the thermal portion between the first circumferentially formed disk-shaped flange mating feature and the second circumferentially formed disk-shaped flange mating feature, the set of annular flanges having a radial width less than at least one of the first radial width and the second radial width. (i) a first circumferentially formed disk-shaped flange mating feature extending radially from a proximal end of the thermal portion of the electrode, the first circumferentially formed disk shaped flange mating feature defining a first radial width to interface with the swirl ring said first disk-shaped flange mating feature including a sealing member configured to form a dynamic seal with the swirl ring so to limit a flow of a gas from a forward side to a rearward side of said first disk-shaped flange mating feature, (ii) a second circumferentially formed disk-shaped flange mating feature extending radially from a distal end of the thermal portion of the electrode to define a second radial width to interface with the swirl ring, and (iii) a thermal exchange surface region defined by a generally cylindrical portion of the thermal portion between the first disk-shaped flange mating feature and the second disk-shaped flange mating feature, the thermal exchange surface region defining a set of annular flanges extending from the thermal portion between the first circumferentially formed disk-shaped flange mating feature and the second circumferentially formed disk-shaped flange mating feature, the set of annular flanges having a radial width less than at least one of the first radial width and the second radial width.