Waterjet cutting is one of the most versatile and precise material processing technologies available today. Whether you’re cutting metal, plastic, glass, or composite materials, waterjet technology offers extreme accuracy without introducing heat-related distortions. In this blog, we will explore the fundamentals of waterjet cutting, its benefits, and the key components that make up a waterjet cutting system.
What is Waterjet Cutting?
Waterjet cutting is a controlled, accelerated erosion process that utilizes high-pressure water—sometimes combined with abrasive particles—to cut through a wide variety of materials. Unlike other cutting methods, waterjet cutting does not introduce heat, ensuring that materials remain unchanged in their structural integrity.
Key Benefits of Waterjet Cutting
- Tight Tolerances – Achieve precision cuts with minimal deviation.
- Cuts Materials Up to 12” Thick – Handles a wide range of materials and thicknesses.
- No Heat Affected Zone (HAZ) – Eliminates warping and material alteration caused by heat.
- Less Material Waste – Efficient nesting and common-line cutting reduce scrap.
- Superior Edge Finish – Achieves smooth, high-quality cuts without the need for secondary processing.
Waterjet technology requires a medium capital investment, typically ranging from $200,000 to $500,000, but offers exceptional versatility by cutting nearly any material at virtually any thickness. With a typical precision of +/- 0.005 inches for most materials, waterjet cutting is suitable for applications demanding tight tolerances.
Unlike other cutting processes that generate a kerf—a material removal gap—waterjet cutting produces a narrow kerf, typically around 0.030” – 0.040” for abrasive waterjet (AWJ) and as small as 0.005” – 0.010” for pure waterjet (WO). Additionally, modern nesting software allows for efficient material utilization, improving cost efficiency and reducing waste.
Waterjet Cutting System Overview
A typical waterjet cutting system comprises several critical components:
- Pump – The heart of the system, providing high-pressure water. Two types exist:
- Intensifier Pump – Flexible, on demand, variable displacement pumps which can operate between 15,000 to 90,000 psi Direct Drive Pump – Fixed, positive displacement pumps which are typically lower cost up front, but more expensive to operate and maintain
- Cutting Head – Converts high-pressure water into a cutting stream:
- Houses the orifice, mixing chamber, and nozzle.
- Utilizes pneumatic-assisted actuators for precision control.
- Available in AWJ and WO configurations.
- Abrasive Feed System – Includes bulk feed and mini hopper for controlled abrasive delivery.
- Motion System – Determines cutting accuracy and machine movement:
- Cantilever Design – Offers open access on three sides, great for standard sheet sizes .
- Gantry Design – Provides superior rigidity and is ideal for large-scale cutting applications.
- Tank & Cutting Surface – Supports materials and dissipates water stream energy.
- Slat bed and jet brick surfaces are used for different applications.
- Controller – The brain of the system, managing the cutting process. Typical key features for CNC waterjet controllers include
- A graphical based user interface
- Jumping functions – jump to program start, start of cut, middle of cut
- CNC program modification – rotation, array, nesting
- Consumables tracking & management
- Fully integrated & remote control of peripheral equipment – pump, bulk abrasive hopper, mini hopper, etc
Choosing the Right Waterjet System
At Flex Machine Tools, we provide industry-leading waterjet solutions designed for maximum efficiency and precision. Whether you’re cutting intricate designs or handling heavy-duty manufacturing, our waterjet systems offer the reliability and performance you need.
Ready to explore the power of waterjet cutting? Contact us today to learn more!
