The growing need in the manufacturing industry for more advanced applications and the versatility of waterjet technology is a key reason why water jet cutting is now being used far more on shop and factory floors, often replacing machine tools.

The 3D cutting capabilities of waterjet broadens the range of potential applications, “Manufacturing shops can expand the types of material they process with waterjet to materials such as composite and advanced aerospace alloys,” explained Gavin Bell, General Manager of Water Jet Sweden.

Bell added, “Waterjet cutting is increasingly being selected because manufacturers want to invest in technology that provides their business with increased flexibility. Added to that, waterjets have become faster, more accurate, and less expensive to operate.” 

For most shops, faster cutting results in higher throughput; better accuracy means they can tackle more applications with tighter accuracy requirements; and equipment that is less expensive to operate means a better return on investment.

Manufacturing is also shifting from the traditionally held break-fix mentality. Manufacturers now want optimum uptime and reliability to enable more predictable maintenance schedules for their waterjet cutting machines.

Efficiency and intelligence are key trends driving waterjet technology today. “It’s about rapid diagnosis of problems, how to quickly fix those problems and taking the subjectivity of the operator out of the maintenance equation. Uptime is key to productivity and profitability,” said Bell.

Waterjet users have several key priorities to improve and optimise waterjet technology:

•    Improved cutting speed
•    Abrasive and water utilisation and management
•    Predictability and length of maintenance intervals as well as downtime
•    Reduced total cost of ownership 
•    Improved serviceability
•    Reduced capital cost
•    Improved ease of use and ease of setup
•    Increased energy efficiency

Software & Connectivity

A recent AMRC report suggested that the key driver in the increased popularity of waterjet machines in the manufacturing industry is the improvement in software which plays a vital role, not only in connecting factory-floor machines but also in making it easier for relatively inexperienced users to programme the cutting and achieve the desired result.

“Connected machines can supply data such as predictive maintenance intervals and optimised machine operation for specific jobs to continually improve the cutting process. Linking all of that data provides improved efficiency, accuracy, and reliability of waterjet systems,” explained Bell.

“And by employing modern software design principles, a new and more intuitive user experience is provided allowing less need for waterjet-specific expertise, faster user learning, and significantly more flexibility for automation of the workflow.” 

The impact of this improved efficiency enables shops to increase production and produce better quality parts while simultaneously improving the reliability of their manufacturing process. Software is also critical in the emergence of newer applications, such as smaller parts or even micro-sized parts that shops are now manufacturing with the latest waterjet cutting machines.

With ultra-precise cutting methods and the ability to leave a smooth edge lasers are often considered an alternative to waterjet cutting but they also transfer enormous amounts of heat into a workpiece as they cut it. This results in a large HAZ that extends out from the site of the cut and can potentially affect the physical properties of the workpiece to have an adverse effect on the final product. Because waterjet cutting doesn’t transfer nearly as much thermal energy, it is ideal for avoiding issues related to HAZ. To meets parts tolerances particularly in new and experimental composites manufacturing, waterjet cutting is therefore proving to be the ideal part cutting solution.