Waterjet cutting online: Guaranteed 20 % cost savings

Waterjet cutting is a cold cutting process that separates material by erosion. Water is compressed to extremely high pressure (up to 6,000 bar) and forced through a tiny nozzle. The result is a supersonic jet of water that cuts the workpiece precisely without subjecting it to thermal or mechanical stress. For hard materials, a sharp-edged abrasive is added to the water, which multiplies the cutting performance. The entire process is CNC-controlled for maximum precision.

Almost any material can be cut with a water jet. Soft materials such as rubber, foam or seals are cut with pure water. An abrasive is used for hard materials. These include almost all metals (steel, aluminum, titanium, copper), stone (marble, granite), ceramics, glass (including bulletproof glass), plastics (acrylic glass, PVC) and modern composite materials such as carbon (CFRP). This enormous variety of materials is one of the greatest advantages of the process.

The actual "tool" is the water jet itself, there is no direct tool contact. The system consists of a high-pressure pump, which generates the water pressure, and a CNC-controlled cutting head. This focuses the water jet through an extremely small nozzle made of diamond or sapphire. For abrasive cutting, a mixing chamber is added in which the cutting agent (usually garnet sand) is mixed into the water. It is a low-wear, non-contact process.

The achievable tolerances are very high and depend on the material thickness and cutting speed. Usual general tolerances are in the range of ±0.1 mm to ±0.3 mm, which corresponds to tolerance class "medium" (m) according to DIN ISO 2768. For demanding applications, significantly tighter tolerances of up to ±0.05 mm can be achieved by using slower cutting speeds or 5-axis cutting heads that correct the cutting angle error.

The difference lies in the cutting medium. With the Pure water cutting only the pure, highly concentrated water jet is used to separate soft, cellular or fibrous materials (e.g. foam, rubber). With the Abrasive cutting a sharp-edged abrasive (usually garnet sand) is added to the water jet in a mixing chamber. The water jet serves as an accelerator for the sand grains, which then erode hard materials such as metal, stone or glass.

Due to the variety of materials and the cold cut, the process is used in numerous industries. The main users are mechanical and plant engineering (precision parts), aerospace (titanium, composite materials), the automotive industry (prototypes), medical technology and advertising technology (logos made of acrylic glass). Other important sectors include architecture (tiles, stone inlays), the electrical industry (copper parts) and even the food industry.

The process is ideal for products that require precision, complex contours and a gentle cut. Typical products include machine parts made of steel or aluminum, flanges, rubber seals, precisely fitting foam inserts for packaging, individual floor mosaics made of tiles or stone, letters and logos for advertising technology as well as prototypes and small series components made of almost any conceivable material, especially if it is thick or heat-sensitive.

The biggest advantage is the "cold cut": no heat is generated, therefore no thermal distortion, no hardening and no structural changes to the material. Further advantages are the enormous variety of materials (including thick, reflective or composite materials), high precision, burr-free cut edges (often no post-processing required) and environmental friendliness, as no harmful gases or vapors are produced. It is also a very gentle, stress-free cutting process.

Compared to thermal processes such as laser or plasma cutting, the cutting speed is often lower, especially for thin sheets. This can lead to higher unit costs for simple large series. In addition, a slight taper (V-shape) occurs at the cutting edge, but this can be compensated for with modern 5-axis technology. The energy consumption of the high-pressure pumps is high and the disposal of the abrasive sludge requires a certain logistical effort.

Manufacturing at FACTUREE is a simple online process. You upload your 3D CAD or DXF data directly to our platform, select the desired material from a huge selection and define the quantity and other specifications. Within a short time, usually on the same day, you will receive a binding offer. Once you have placed your order, your project is automatically assigned to the ideal manufacturer from our network and you receive your finished parts on the desired date.

Online manufacturing via FACTUREE offers enormous speed and efficiency benefits. You get immediate access to a huge network of manufacturing capacities and don't have to search long for a suitable supplier. The process is transparent and simple: upload CAD data, receive a quote immediately and order online. Thanks to the competition in the network, you benefit from optimized prices and the shortest delivery times. Everything is handled via one platform - from a single source.

Yes, absolutely. FACTUREE specializes in the production of prototypes, individual parts and small batches. There is no minimum order quantity. As a tool-free process, waterjet cutting in particular is ideal for the economical production of batch size 1. You can easily request a single component for validation, for a repair or for a one-off project and receive the same high quality and fast service as with a series order.

FACTUREE ensures the highest quality through a carefully audited production network whose partners are all ISO 9001 certified. Their technical drawings with the specified shape and position tolerances are the binding basis for production. Our partners use modern machines, often with 5-axis cutting heads that actively compensate for typical cutting angle errors. Continuous quality management and test protocols ensure compliance with your specifications.