Frequently Asked Questions
Advantages of WaterJet Cutting
Unlike processes such as laser or plasma cutting, waterjet cutting does not generate heat. This eliminates the risk of heat distortion or a heat-affected zone (HAZ) that can alter the material properties, especially in metals, plastics, and composites.
Waterjets can produce extremely precise cuts, with tolerances as tight as ±0.10mm. This makes waterjet cutting ideal for intricate designs, small parts, or high-tolerance work. The kerf (Jet width), can be from ⌀0.10mm for Water Only applications, upto ⌀1.00mm for Abrasive cuts.
Waterjet cutting can work with a wide variety of materials, including metals (steel, aluminum, titanium), stone, glass, ceramics, composites, plastics, rubber, and more. This makes it an adaptable solution for different industries, including aerospace, automotive, manufacturing, and construction.
Waterjet cutting can work with a wide variety of materials, including metals (Since the cutting process is cold (there is no thermal input), waterjet cutting does not cause material warping, bending, or deformation that could otherwise result from heat-based cutting methods.
The cutting process is highly efficient, and waterjets can make very precise cuts with minimal kerf (the width of the cut). This results in reduced material waste, making it more cost-effective, especially for expensive materials.
The cutting Waterjet cutting excels at producing complex, intricate shapes, and fine details with minimal burrs or edges that require additional finishing. This is particularly useful for parts with sharp corners, curves, or other challenging geometries.
Waterjet cutting uses water (with added abrasives in some cases) as the cutting medium, making it a more environmentally friendly option compared to other methods that may produce toxic fumes or require chemical cutting agents.
Unlike mechanical cutting methods that rely on tools that wear out over time, waterjets use high-pressure water (and abrasives, in some cases), so there is no tool wear. This allows for longer production runs with consistent performance.
Waterjets can effectively cut through materials of varying thicknesses, from thin sheets to several inches thick, making it suitable for a wide range of applications.
Waterjet cutting produces smooth edges and precise cuts, there is often little to no need for additional post-processing like grinding or polishing, saving both time and money.
Waterjet cutting is generally safer than other cutting methods like lasers or plasma because there are no high temperatures or fumes generated, reducing the risk of fire or health hazards. The primary risks involve high-pressure water, but proper safety equipment and procedures can mitigate these.
Waterjet cutting requires minimal tooling, which can significantly lower setup costs compared to methods that require expensive dies, molds, or specific tools.
machine costs
It is difficult to give a specific answer. However a new Abrasive WaterJet Cutting machine, including delivery, installation and training will cost in the region of £120,000 for an entry level unit.
Used machines infrequently come to market, however, can normally be sourced for £35,000. Please contact us, we may have what you are looking for.
Abrasive
In order to cut metal a abrasive (sand) is added to the stream.
This can be a suspension system, adding abrasive to the water prior to pressurising the slurry, normally used for onsite cutting.
Or, more commonly used an entrainment system, where sand is added at the cutting nozzle.
Anything harder than the abrasive cannot be cut. The industry standard media is Garnet, with hardness of 7.5 on Mohs scale.
comparible processing costs
Waterjet Cutting is more expensive than Laser or Plasma cutting, when comparing a part cost.
However the process is capable of processing a wider range of materials and thickness’.
Particularly suited to low volume / prototyping, or applications were secondary operations are required WaterJet Cutting can often offer a cost advantage.
Frequently Asked Questions
Disadvantages of WaterJet Cutting
Waterjet cutting is generally slower than other cutting technologies like laser, plasma, or CNC machining, particularly for thick materials. While it provides high precision, the cutting speed can be a disadvantage when working with large volumes of material or when speed is a priority.
The cost of waterjet cutting machines, especially high-pressure systems and those with advanced features like 5-axis capabilities, can be quite high. This makes the initial investment more expensive compared to other cutting technologies, which might deter small businesses or individuals.
Waterjet cutting works well with a variety of materials, but for cutting harder materials like metals at greater thicknesses, an abrasive waterjet (which adds an abrasive material to the water) is required. This adds cost, complexity, and wear on components.
Although waterjet cutting is efficient, it does generate water and abrasive waste, which requires proper disposal and environmental considerations. For abrasive waterjet cutting, the disposal of spent abrasives can also become an issue, especially if large amounts of material are being cut.
While waterjets can cut through thick materials, they are generally not as effective at cutting through extremely thick or dense materials (such as very thick steel or certain composites) compared to methods like laser or plasma cutting. The speed and effectiveness decrease as material thickness increases.
While waterjet cutting typically produces a smooth edge, some materials, especially thicker or harder ones, may exhibit a rougher edge finish that could require additional finishing. The edge quality can sometimes vary depending on factors such as water pressure, material type, and cutting speed.
For very thin materials (such as thin sheets of metal or delicate fabrics), waterjet cutting may not be the most efficient or cost-effective option. Other methods like laser cutting may provide more precise cuts with less energy consumption.
Waterjet cutting machines require regular maintenance, especially with high-pressure pumps, nozzles, and abrasive handling systems. Parts can wear down over time due to the abrasive nature of the process, leading to maintenance costs and potential downtime. Additionally, waterjet systems require a clean water source, which may necessitate water filtration systems and additional maintenance.
Waterjet cutting machines can be large and require significant space in a workshop or manufacturing facility. For companies with limited space, this can be an issue, especially for large-format cutting machines or multi-axis systems.
Waterjet cutting, particularly at high pressures, can be noisy and produce vibrations during operation. This could be a concern in environments where noise levels need to be controlled or where worker comfort and hearing protection are factors.
Some materials, such as certain ceramics or hard composites, may present challenges in achieving the same level of precision and clean cuts as with metals or softer materials. For these, specialized setups or other cutting technologies might be needed.
High-pressure waterjet systems require significant amounts of power to operate, especially when cutting thicker materials. This can lead to high electricity costs and requires an adequate power supply for proper operation.
Waterjet cutting requires minimal tooling, which can significantly lower setup costs compared to methods that require expensive dies, molds, or specific tools.
While waterjet cutting is an extremely versatile and precise cutting method, it does come with certain limitations, such as slower cutting speeds for large volumes, higher operational and maintenance costs, and potential waste disposal concerns. The decision to use waterjet cutting should depend on the specific requirements of the job, including material type, thickness, speed, and quality needs.