A torch tip for a plasma arc torch, the torch tip comprising: a body having a first end and a second end, the first end of the body configured to attach to the plasma arc torch; an end wall disposed at the second end of the body; a plasma exit orifice formed in the end wall at the second end of the body; at least two castellations formed on an exterior surface of the end wall, each castellation having: a first sidewall and a second sidewall on the end wall at the second end of the body, and a castellation width defined by a first distance between the first sidewall and the second sidewall, the first distance is measured across an outer diameter of the castellation at the second end of the body; the torch tip further comprising: at least one slot disposed between the two castellations, each slot having a slot floor and a slot width, the slot width being defined by a second distance between a first sidewall of the first castellation and a second sidewall of the second castellation adjacent the first castellation the second distance is measured across an outer diameter of the slot the second end of the body, the slot width increasing with axial or radial distance away from the plasma exit orifice; the torch tip is characterised in that the slot width is at least twice the castellation width. a body having a first end and a second end, the first end of the body configured to attach to the plasma arc torch; an end wall disposed at the second end of the body; a plasma exit orifice formed in the end wall at the second end of the body; at least two castellations formed on an exterior surface of the end wall, each castellation having: a first sidewall and a second sidewall on the end wall at the second end of the body, and a castellation width defined by a first distance between the first sidewall and the second sidewall, the first distance is measured across an outer diameter of the castellation at the second end of the body; the torch tip further comprising: at least one slot disposed between the two castellations, each slot having a slot floor and a slot width, the slot width being defined by a second distance between a first sidewall of the first castellation and a second sidewall of the second castellation adjacent the first castellation the second distance is measured across an outer diameter of the slot the second end of the body, the slot width increasing with axial or radial distance away from the plasma exit orifice; the torch tip is characterised in that the slot width is at least twice the castellation width. a first sidewall and a second sidewall on the end wall at the second end of the body, and a castellation width defined by a first distance between the first sidewall and the second sidewall, the first distance is measured across an outer diameter of the castellation at the second end of the body; the torch tip further comprising: at least one slot disposed between the two castellations, each slot having a slot floor and a slot width, the slot width being defined by a second distance between a first sidewall of the first castellation and a second sidewall of the second castellation adjacent the first castellation the second distance is measured across an outer diameter of the slot the second end of the body, the slot width increasing with axial or radial distance away from the plasma exit orifice; the torch tip is characterised in that the slot width is at least twice the castellation width. at least one slot disposed between the two castellations, each slot having a slot floor and a slot width, the slot width being defined by a second distance between a first sidewall of the first castellation and a second sidewall of the second castellation adjacent the first castellation the second distance is measured across an outer diameter of the slot the second end of the body, the slot width increasing with axial or radial distance away from the plasma exit orifice; the torch tip is characterised in that the slot width is at least twice the castellation width.