A set of consumables for a plasma arc torch assembly, comprising: an electrode (210,210') including a main body that extends between a proximal end and a distal end with a distal end face, the distal end face being substantially flat and perpendicular to a longitudinal axis of the electrode (210,210'), the main body including an external surface, comprising: a longitudinal portion that is substantially parallel to the longitudinal axis of the electrode (210,210'); a tapered portion that has a constant interior taper angle in the range of 30° to 50° and extends between the longitudinal portion and the distal end face; and a transition portion (230,230') that connects the tapered portion to the longitudinal portion; and a nozzle (250,250') that is installable around the electrode (210,210'), the nozzle including a main body defined, at least in part, by an outer surface and an inner surface, wherein: the transition portion defines a smooth, rounded transition between the longitudinal portion and the tapered portion; and the inner surface of the nozzle (250,250') is disposed opposite to and mirroring the tapered portion of the electrode (210,210'), opposite to and mirroring the transition portion (230,230') of the electrode, and opposite to and mirroring at least a portion of the longitudinal portion of the electrode (210, 210') so that the external surface of the electrode (210, 210') and the inner surface of the nozzle (250, 250') define a plasma gas channel (280,280') therebetween having a constant width perpendicular to the external and inner surfaces. a longitudinal portion that is substantially parallel to the longitudinal axis of the electrode (210,210'); a tapered portion that has a constant interior taper angle in the range of 30° to 50° and extends between the longitudinal portion and the distal end face; and a transition portion (230,230') that connects the tapered portion to the longitudinal portion; and a nozzle (250,250') that is installable around the electrode (210,210'), the nozzle including a main body defined, at least in part, by an outer surface and an inner surface, wherein: the transition portion defines a smooth, rounded transition between the longitudinal portion and the tapered portion; and the inner surface of the nozzle (250,250') is disposed opposite to and mirroring the tapered portion of the electrode (210,210'), opposite to and mirroring the transition portion (230,230') of the electrode, and opposite to and mirroring at least a portion of the longitudinal portion of the electrode (210, 210') so that the external surface of the electrode (210, 210') and the inner surface of the nozzle (250, 250') define a plasma gas channel (280,280') therebetween having a constant width perpendicular to the external and inner surfaces. the transition portion defines a smooth, rounded transition between the longitudinal portion and the tapered portion; and the inner surface of the nozzle (250,250') is disposed opposite to and mirroring the tapered portion of the electrode (210,210'), opposite to and mirroring the transition portion (230,230') of the electrode, and opposite to and mirroring at least a portion of the longitudinal portion of the electrode (210, 210') so that the external surface of the electrode (210, 210') and the inner surface of the nozzle (250, 250') define a plasma gas channel (280,280') therebetween having a constant width perpendicular to the external and inner surfaces.