A Guide to Custom Waterjet Cutting

To create parts at the cutting edge of precision detailing, finding water jet services is often the sharpest solution. Here’s a guide to custom water jet cutting, and the benefits it provides.

To continuously produce precision-engineered parts that are often small, intricate or carved from heavy-duty materials, you come to rely on an ingenious method of cutting that offers 100% accuracy, every time. We are talking about CNC water jet cutting technology.

It’s sometimes hard for those outside the industry to understand why finding a custom water jet cutting service is so vital to producing detailed prototypes Or, for consignments of parts needed quickly.

Meanwhile, the team at Custom Moulded Polyurethane get so passionate about the potential of water jet technology, that we welcome a challenge from all sorts of different organisations. Not just those interested in cutting polyurethane, but anyone who wants to use our water jet equipment, CAD capabilities and skills to slice through anything.

So, we decided to bring together some of our insights to create a guide to custom water jet cutting.

What is water jet cutting?

Water under intense pressure, directed through a small nozzle, can cut through a diverse range of materials, from stone to foam as we discuss below.

The ability to control that water stream to a micrometre (1000 times smaller than a millimetre) opens up an infinite world of possibilities. Advanced waterjet equipment can do that.

It’s not just about the power of water to cut precisely though, it can also cut deep.

To show you the difference in capabilities between laser cutting and water jet cutting equipment, lasers create a precise incision on stone and metal to a depth of around 2.5cm. When you use sharp points of water, it can cut the same materials to a depth 10 times greater.

Another important aspect of water jet cutting is its environmental implications. It doesn’t use heat or chemicals to create the perfect finish on a precision-engineered part.

What could be more sustainable than water? It also involves no fumes or allergens.

Lastly, by using water to create prototypes that are perfect in form and function, you can also protect the structure and tensile properties of your materials. For example, cutting through a soft foam or pliable rubber with water jets doesn’t distort it.

One of the reasons water jet cutting is now so common is that it guarantees no burrs, burns, buckling, shredding or flaking. Just the perfect cut to create a smooth edge.

Related article: Our Water Jet Cutting Process Explained

What can water jets be used for?

You name it, water jets can cut it!

The possibilities include metals and stones; even granite and marble.

As it’s quick and exacting, that high-pressure water jet can also slice through some types of glass, fibreglass and ceramics, without cracking them.

It also swiftly shapes construction foams, rubber and other soft materials, with superb detailing.

The list of things that can be shaped using custom water jet cutting also includes leather, cardboard, cloth and even paper!

The ability to control flow and motion of the water stream to such a large degree is why water jet cutting equipment can be used on such a wide range of materials and can penetrate up to 24 inches for deeper slices.

Harder materials – such as granite, marble and thick metal can be precision cut with water, but sometimes require that the cutting equipment also uses an abrasive element.

A carefully controlled amount of abrasive particles are mixed with the water in a ceramic tube within the nozzle, to create a specially formulated slurry that travels at high speed when expelled.

Wood, rubber, glass, steel, aluminium, plastics and other less resistant materials can be shaped and patterned without this abrasive additive, using the clean cutting power of H2O.

Related Article: How Accurate is Water Jet Cutting?

How water jet cutting works

There are generally two types of water jet cutting machines – one using purely water, and an alternative that can introduce an abrasive element, too. More on that later.

The basic premise is that when water is forced out of a nozzle, under very high pressure, it is strong enough to slice cleanly and quickly through various surfaces. The outlet of the nozzle – sometimes referred to as the “jewel” – leads to a tiny hole – which can be varied in size to change the effect.

Modern technology means that the equipment used for water jet cutting projects is infinitely programmable. The motion control element of the machine dictates the motion and shape of the water cutting stream.

Using CAD software, the motion control can be programmed to carry out even complex contour cutting, potentially working around existing features, making it useful for a number of industries.

Using pressurised water to create cuts is very precise, ensuring clean and accurate shaping around even the most intricate machine part. The equipment can easily and cost-effectively be set up for one-offs, or to automate long cutting runs efficiently.

As the flexible nozzle head allows for angled cuts, it’s also possible to automate a series of clean vertical and horizontal cuts.

Thanks to the powerful pumps used, the water can be forced out at a varied level of pressure depending on the project. This ensures precision finishes but also fuel efficiency, as the energy used is highly focused on the cutting process.

Related Article:Who needs industrial water jet cutting?

Where Water Jet cutting started vs where it is now

The first use of pressurised water as a cutting tool was thought to be during the American Gold Rush in the 1850s.

Nowadays, custom water jet cutting relies on adept use of the software inherent in the most advanced equipment. The direction, depth and detail can be altered to an endless array of possibilities.

Also, the process often uses abrasive materials added to the jet of water. This can be crucial when it’s slicing through thicker, harder substrates. The right mixture creates the correct friction to delicately engrave metal as thin as 0.2 mm too.

The best custom water jet cutting machines also filter the water carefully, before it travels to the pump and inlet check valves. Then, the composition of the water mix can be amended by waterjet technicians, before being put under pressure by the intensifier, and passing through to the cutting heads. The ability to control the intensity of the water stream comes from the accumulator, a device that smooths the pressure.

As you would expect, quality control sensors continuously measure output and abrasive metering.

Related article: What you Need to know about our Industrial Water Jet Cutting

Advantages of water cutting compared to other methods

Among the benefits of using water jet cutting technology is the absence of any heat. Most alternative cutting methods use high temperatures – or create friction in the process. So, for materials or parts that are temperature or friction sensitive, water has the advantage of being the “kindest cut”.

Using water to cut materials is also a clean and safe method. It reduces the chance of impurities lingering on the cut edges.

Are there any materials not suitable for water jet cutting? Due to the force within the water jet, tempered glass is not a suitable substrate, as it could shatter. Any composites that could be impacted by moisture are also not appropriate for precision cutting with water.

Beyond that, water jet technology can make quick work of precision shaping just about anything! In a highly controllable, clean and efficient way.

Related article: 5 things you need to know about our water jet cutting services

Crafting the perfect part with water jet technology

What this guide to water jet cutting needs to emphasise, is this is not just a highly precise way to create often complex parts. It’s also fast!

Custom Moulded Polyurethane can swiftly deploy its advanced CNC tech to match even a demanding brief. There are no specialist tools or moulds to craft. We can also set up any secondary finishing stages quickly, often facilitating a same-day turnaround in prototyping.

When you commission custom water jet cutting services with us, we can also meet bulk orders for precision-engineered parts to tight deadlines.

Are you ready to dip your toe in, and test water jet cutting? Get in touch and we can quote to cut any material and part, to any degree of complexity.