5 Steps to Choose a Waterjet Cutting Machine

Picking the right waterjet cutting machine is crucial for your manufacturing needs. Here's a quick guide to help you choose:

1. Check Your Material Needs: Determine if you need pure or abrasive waterjet cutting based on materials and thickness.
2. Define Production Goals: Balance speed, accuracy, and output requirements.
3. Look at Machine Features: Consider control systems, automation options, and axis capabilities.
4. Add Up All Costs: Factor in purchase price, operational costs, maintenance, and potential downtime.
5. Check Service Options: Evaluate manufacturer support, training, repairs, and parts availability.

Quick Comparison:

By following these steps, you'll find a waterjet cutting machine that fits your needs and budget, boosting your manufacturing capabilities.

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Step 1: Check Your Material Needs

First things first: what are you cutting? This is key when picking a waterjet cutting machine.

Waterjet cutting is super versatile. It can slice through tons of different materials with precision. But here's the catch: different materials need different approaches. So, you need to match your needs to the right machine.

Materials and Their Thickness

There are two main types of waterjet cutting machines: pure waterjet and abrasive waterjet systems. Your choice depends on what you're cutting most often.

Pure Waterjet Cutting

This one uses just high-pressure water. It's great for softer stuff like:

• Foam (up to 2-3 feet thick)
• Rubber (up to 10 inches thick)
• Paper and cardboard
• Soft plastics
• Food products

The paper industry loves pure waterjet cutting. It can slice through thick stacks of paper like butter. The food industry's a fan too - it's great for cutting meats, fish, bread, and even frozen foods.

Abrasive Waterjet Cutting

For tougher materials, you'll want abrasive waterjet cutting. It mixes tiny abrasive particles (usually garnet) with the water stream. This combo can cut through:

• Metals (including hardened tool steel, aluminum, titanium)
• Glass (up to 7 inches thick)
• Stone and ceramics
• Composites like carbon fiber
• Hard plastics

Abrasive waterjet cutting is a beast. It can cut through 12 inches of stainless steel. Some fancy machines can handle even thicker stuff.

Here's a quick comparison to help you match your materials to the right machine:

When you're thinking about your material needs, don't just consider the types of materials. Think about how thick they are too. Waterjet cutting can handle some impressive thicknesses, but remember: the thicker the material, the slower the cutting speed.

"Waterjet cutting provides a superior edge quality that is unmatchable by any other processes." - TechniWaterjet

This quote nails one of the big perks of waterjet cutting: clean, precise cuts without heat-affected zones. This is huge for materials that don't play nice with heat - it keeps them from getting distorted or changing their properties.

Waterjet cutting isn't just versatile in terms of what it can cut. It's also about the quality of the cut. Take fibreglass and carbon fibers, for example. Waterjet machines can produce a stream as thin as 0.1mm. That's incredibly precise cutting without any risk of heat damage.

As you're sizing up your material needs, make a list of all the materials you work with regularly and how thick they usually are. This list will be super helpful when you're comparing different waterjet cutting machines and what they can do. By really understanding your material needs, you'll be in a better position to choose a machine that not only works for what you're doing now but also gives you room to grow in the future.

Step 2: Define Your Production Goals

Choosing the right waterjet cutting machine boils down to matching your production needs with the machine's capabilities. Let's break it down:

Output and Speed: The Balancing Act

Here's the deal: You want speed, but you also need accuracy. It's a trade-off.

James Daugherty from Flow International Corp. puts it this way:

"Cut quality, as it pertains to edge finish, is extremely important in many waterjet applications."

So, if you're making parts for rockets, you might need to slow things down a bit. But if you're cutting simple shapes for signage? You can crank up the speed.

Material Matters

Thickness changes everything. Check this out:

• 6 mm stainless steel? You're zipping along at 6 inches per minute.
• 20 mm stainless steel? You're crawling at 2 inches per minute.

That's a big difference. Plan accordingly.

Pressure: More Is Faster

Want to cut faster? Crank up the pressure:

• 40,000 psi = Mach 3 (760 m/s)
• 60,000 psi = Even faster than Mach 3 (1020 m/s)

Higher pressure means quicker cuts, especially on thinner materials.

Table Size: Go Big or Go Home?

Your table size affects how much you can cut and how flexible you can be:

• Small tables: 2 feet square
• Big tables: Up to 6 by 12 feet

Want to boost efficiency? Consider a table big enough for two workstations. You can cut on one side while loading up the other.

Money Talks: Cost vs. Output

More power costs more money. Here's a quick breakdown:

But remember, more power often means more output. For big jobs with identical parts, multiple small nozzles might be more cost-effective than one big one.

How Precise Do You Need to Be?

Waterjet cutting can get pretty darn accurate:

• Most machines: 0.002″ (0.05 mm)
• Top-notch machines: Down to 0.001″ (0.025 mm)

Steve Szczesniak from Mitsubishi adds:

"The slower you cut, the better the surface finish you will achieve and the better the accuracy will be."

So, if you need super-precise cuts, be prepared to take it slow.

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Step 3: Look at Machine Features

When picking a waterjet cutting machine, you need to focus on features that boost productivity and expand your cutting abilities. Let's break down the key stuff:

Controls and Automation Options

The control system is your machine's brain. It handles everything from how you interact with it to how it moves and positions the cutting nozzle.

Basic vs. Advanced Controls

Basic controls work for simple cuts. But if you want to max out efficiency and tackle tricky projects, you might want something fancier, like Hypertherm's Edge Connect™ Controller.

Hypertherm says:

"EDGE Connect is the next generation of Hypertherm's industry leading automated control systems."

This system steps up your cutting game and comes in a tough industrial case to handle rough shop conditions.

Cool Automation Features

• Auto lead-ins
• Smart part nesting
• Better cornering and pump control
• Multiple ways to pierce different materials

These features can seriously speed up your work and cut down on manual tasks.

Machine Movement Types

How your machine moves determines what kinds of parts you can make. There are two main types:

3-Axis Machines

These move left/right, front/back, and up/down. They're great for:

• Simple cuts on flat stuff
• Basic parts without fancy shapes
• Car parts and electronics

5-Axis Machines

These add two more ways to rotate, letting you do more complex cuts:

• Can cut at angles up to 60 degrees
• Perfect for intricate shapes
• Used in aerospace and medical implants

Here's a quick comparison:

Real Performance Numbers

Check out these stats from a high-end system like the Machitech Waterjet:

• Cutting speed: 500 inches per minute
• Max speed: 1000 inches per minute
• Repeatability: 0.001″
• Positioning accuracy: 0.002″

These numbers show how precise these machines can be.

When deciding, think about what you need now AND later. A 3-axis might work for simple stuff, but a 5-axis could open doors to new, complex projects and markets.

Step 4: Add Up All Costs

Buying a waterjet cutting machine? Don't just look at the price tag. Let's break down the real costs of owning one of these bad boys.

Purchase and Upkeep Costs

Waterjet cutting machines come in all shapes and sizes:

• Budget models: $30,000 - $60,000
• Mid-range commercial: $60,000 - $200,000
• High-end custom systems: $200,000 - $400,000+

But that's just the beginning. Here's what else you're in for:

1. Operational Costs

You're looking at $15 to $30 per hour to run these machines. Here's the breakdown:

• Abrasive (70% of the cost)
• Electricity
• Wear parts
• Water

2. Abrasive Expenses

Garnet, the go-to abrasive, costs about 25 cents per pound. For metal cutting, you'll burn through 1 to 2.3 pounds per minute. That's $110 to $220 daily just for abrasive.

3. Utility Bills

• Water: $1,200 - $2,500 yearly
• Electricity: $3,700 - $9,400 yearly (running 6 hours a day)

4. Wear and Tear

Expect to shell out $7,700 to $32,000 annually on replacing worn parts. Here's the nitty-gritty:

5. Maintenance and Downtime

Set aside $0.50 to $2 per hour for maintenance and potential downtime.

Here's the big picture - annual costs for a typical waterjet cutting operation:

Keep in mind, these numbers can swing based on your specific setup. A 5-axis machine, for example, will cost more to run than a 3-axis system.

Want to keep costs down? Here are some tips:

1. Get a water treatment system if your water's total dissolved solids are over 100 PPM.
2. Stick to a regular maintenance schedule. It'll save you from costly breakdowns.
3. Look into the manufacturer's service plans for repairs and part replacements.

Step 5: Check Service Options

Don't skimp on service and support when buying a waterjet cutting machine. Good service keeps your machine humming and cuts downtime. Here's what to look for:

Manufacturer Reputation and Support

Go for manufacturers with a solid track record. Take Techni Waterjet, for example. They've been around for 35 years and are big players in the game. Their service approach is top-notch:

"Techni Waterjet support guys are always responding on my calls." - Zoran Duckinoski, Emu Energy

• Full-time technicians (no outsourcing)
• Quick installation and training
• Fast response times

Training Options

You need good training to get the most out of your machine. Some manufacturers go the extra mile:

• Semyx Cutting Solutions: on-site, online, and classroom training
• TCI Cutting: tech advice throughout the machine's life

Repair and Maintenance

Fast repairs save you money. Look for:

• 24/7 support (like Semyx offers)
• Remote diagnostics (TCI Cutting does this)
• Nearby technicians

Parts Supply

You need parts fast when something breaks. Check out:

• H2O Jet: helps find part numbers and drawings
• Semyx Cutting Solutions: same-day shipping for most brands

Service Plans

Some manufacturers offer plans to manage ongoing costs. OMAX, for instance, has five different plans to fit various needs and budgets.

Third-Party Service Providers

Don't forget about third-party specialists. They can be lifesavers:

• WaterJet 911: experts in Flow waterjets, repairs various systems
• Fast service for high-pressure systems
• Distributes parts for H2O Jet and Accustream

Finding Local Support

Need local help? Use the Machine Shop Directory. It's a great way to find nearby experts who know waterjet cutting machines inside and out.

Conclusion

Picking the right waterjet cutting machine can make or break your manufacturing game. But don't sweat it - if you've followed our five-step guide, you're on track to make a smart choice that fits your needs and budget like a glove.

We've covered a lot of ground:

• Sizing up your material needs
• Nailing down your production goals
• Checking out machine features
• Crunching the numbers (all of them)
• Digging into service options

Each of these pieces is key to finding your perfect waterjet match.

Here's a quick hit list to keep you on track:

1. Material Matchup: Can it handle your stuff?
2. Production Power: Does it meet your output and precision needs?
3. Machine Muscle: How's the control system? Automation? Axis action?
4. True Cost: Look beyond the price tag - think running costs, upkeep, and potential downtime.
5. Backup Plan: What's the word on the manufacturer? Training? Parts and tech support?

Kevin Lee, Technical Director at Shengen, hits the nail on the head:

"For forward-thinking businesses, adopting cutting techniques such as waterjet is a must."

So there you have it. You're armed with the know-how to choose a waterjet cutting machine that'll take your manufacturing to the next level. Time to make waves in your industry!