Best solution for Water jet Plastic Cutter

The CNC water jet plastic cutter is a computer-controlled machine that uses a supersonic stream of water to slice through most materials, including plastic.

The cutting process takes place when the stream of water is shot through a small diamond orifice, creating an intense pressure that can cut through the plastic material with precision.

You can either use a pure water jet to cut softer materials such as wood, or you can mix abrasives with water and use the mixture on harder materials like metals and stone.

When cutting plastic, you have a few options besides waterjet machines to consider. The most common choices include laser and plasma cutting, but there are some others as well.

However, the real question is: why should you invest in a waterjet machine over alternatives for your plastic production projects? What advantages do they offer?

Well, the very first benefit of waterjet cutting is the fact that it’s a cold-cutting process, meaning there is no heat-affected zone (HAZ) present in the cut material. This can be crucial in plastic cutting, as heat can potentially warp or degrade the material being cut.

Additionally, waterjet cutting also offers a high level of precision and versatility. The stream can be easily manipulated to cut intricate designs, and it can also cut through a wide range of materials with the same machine.

Finally, waterjet cutting leaves a smooth, clean cut, which means that you don’t have to worry about secondary finishing. This can save time and money in the long run, increasing efficiency in the production process.

A waterjet cutting machine typically consists of three main components: a high-pressure pump, an abrasive delivery system, and the cutting nozzle.

First, the pump pressurizes water to an extreme level (30,000–90,000 psi). This water is then shot through tiny jeweled nozzles to form a fine, focused stream (as small as human hair).

If needed, an abrasive substance such as garnet is added to the water stream through the abrasive delivery system, enhancing its cutting power on harder materials.

The high-pressure water stream is then directed onto the plastic material, cutting through it with precision and leaving a smooth edge. The used water and abrasives are collected in a catch tank for disposal.

Waterjet cutting machines provide very high levels of precision and accuracy. They can cut parts with a tolerance (distance between the intended cut and the actual cut) from ± 0.001” (0.025 mm) to ± 0.002” (0.05 mm).

This level of precision can be attributed to the highly controllable cutting head, as well as the fine, focused stream of water and abrasives used for cutting. The absence of heat and no contact of the machine head with the workpiece are also factors in achieving accuracy with waterjet cutting.

Some waterjet machines also offer multi-axis capabilities, allowing for even greater precision and the ability to cut complex shapes in one continuous motion.

The cutting speed of a waterjet is affected by several factors, including the type of pump being used, the size of the nozzle, the thickness and type of material being cut, and what type of abrasive (if any) is being used.

Generally speaking, When a waterjet is operated at 300 MPa (40,000 psi), the water used to cut plastic is propelled at a speed of around Mach 3 (760m/s). However, if the same waterjet is run at 400 MPa (60,000 psi), the water used to cut the same material will be ejected at a speed greater than Mach 3 (1020 m/s).

Waterjet machines are capable of cutting through plastic up to a thickness of 8 to 12 inches. The thickness depends on the material type and the pressure of the waterjet pump, as well as the diameter of the nozzle used by the machine.

Some machines can handle even thicker materials with the right setup and adjustments. If you’re working with thin plastics, it’s possible to stack several layers of plastic pieces and cut them all at once without distortion or other adverse effects.

However, it’s important to note that as the material thickness increases, the cutting speed will decrease.

Waterjet cutting is not limited to just plastics; it’s also commonly used to cut rubber, foam, wood, composites, and glass. The waterjet technology is so efficient that it can cut even the most exotic metals.

In terms of what type of plastic can be cut, waterjet is suitable for cutting acrylic, polycarbonate, Carbon Fiber, Polyvinyl Chloride, Garolite, and various types of polyethylene, among others.

The versatility of waterjet cutting is due to its non-contact, heat-free cutting process, as well as the ability to add abrasives for harder materials.

The PSI in a waterjet cutting machine refers to the pressure at which the water is propelled through the nozzle. This can vary depending on the type of pump being used, but most waterjet machines typically run at pressures between 30,000 to 90,000 PSI.

High pressure is necessary for efficient and precise cutting, and some machines offer the ability to adjust and control the pressure for different materials and thicknesses. However, the more pressure used, the greater the wear and tear on the machine’s components.

Abrasive is often added to the water stream in a waterjet cutting machine to improve its cutting capabilities, particularly to cut thicker plastics. Common abrasives used in waterjet cutting include garnet, aluminum oxide, and silicon carbide. Garnet is considered the most cost-effective and efficient option due to its physical properties.

The type and quantity of abrasive used will vary depending on the material being cut, as well as the desired cutting speed and precision. The abrasives are stored in a hopper and automatically fed into the water stream during cutting.

The quality of the edge finish is how smooth and precise the cut was made on the material. When cutting plastic with a waterjet cutter, you will always get a smooth, precise cut that leaves no sharp burrs or slag.

Not only that, but you can cut multiple shapes on a single sheet of material using shared edges to minimize waste and maximize efficiency. The waterjet cutter has a accuracy of +0.1 mm to +0.2 mm, making it accurate enough to cut clean and precise edges.

Although tap water is acceptable for running a waterjet machine, you should do a quality assessment to ensure that the water quality is optimum for ultra-pressurization. This will help ensure that your equipment lasts longer.

You can first take a water analysis and then use a suitable water treatment system to remove impurities from tap-water, thereby preventing wearing on the machine’s components. The treatment system will depend on the results of the analysis, so it’s important to choose one accordingly.

The cost of a waterjet cutting machine will vary depending on its size, capabilities and brand. A small, basic machine can be purchased for around US$40,000, while a larger and more advanced model can cost upwards of US$200,000.

Before you purchase a machine, consider how much you can afford to spend on it. That includes the cost of purchasing and operating the machine as well as the cost of maintaining it.

The cost to run a waterjet plastic cutter for most jobs is approximately $12 to $35 per hour. However, this figure may vary widely depending on your specific requirements.

Below are a few of the factors that can affect the cost:

Abrasive: Waterjet uses around 3 pounds of abrasive each minute and that can cost 25 cents per pound.

Replacement parts: It costs between $15,000 to $25,000 per year to maintain replaceable parts like pump seals & focusing tubes.

Electricity: The annual cost of running a water jet 6 hours a day will range between $3000 and $9000.

Water consumption: The water jet uses around 0.5 to 1.5 gallons of water every minute, which can cost up to $3000 annually.

Waterjet cutting machines vary in lifespan, but with proper maintenance and care they can last for decades. The consumables used in a waterjet are also long-lasting when compared to other cutting processes such as Plasma and EDM.

The nozzle on the water jet can last for 100 hours, and other parts like the pressure pump last even longer – for about 10,000 hours. This means that you won’t have to replace consumables as often, which saves you money on labor costs.

The waterjet cutting process itself is safe since no fumes or sparks are produced. The low risk of fire also stems from the absence of heat in this kind of cutting.

However, as with any piece of machinery, you should be aware of the risks, and take extra care when working around the machine. Some health concerns include noise and injury from high-pressure water or flying debris.

It is important to have proper training and follow safety protocols when operating a waterjet cutter. Wearing appropriate protective gear, such as earplugs, safety glasses, and gloves, is also necessary to minimize risks.

Proper maintenance is important for any machine, and the same applies to waterjet cutters. These machines are designed with very high-pressure plumbing, which means that wear and tear on them are sure to occur over time.

Generally, If your machine is exposed to high pressure and many on/off cycles, it may require more frequent maintenance. Dirty or hard water can also damage your machine if not treated properly.

You’ll need to replace nozzle parts frequently (daily basis). Pump parts will likely need to be replaced less often, but you should still change them regularly enough as needed.

Still compared to other cutting processes, a waterjet requires less maintenance. Many of its parts last longer, require fewer repairs, and can be used for thousands of hours.

The size and type of waterjet machine you’re interested in purchasing will determine how much space you’ll need for it. Smaller, portable models can fit into a corner of a workshop, while larger industrial models may require dedicated space.

When choosing the right size for your waterjet, keep in mind that it’s measured in terms of the table area where you will put the material to be cut. This is slightly smaller than the physical machine itself.

So make sure to plan for enough space around the table for loading materials, as well as easy access for maintenance and operation.

Working with a waterjet cutter requires training and knowledge of safety protocols. You can’t just use the system without having learned how to operate it properly. And many manufacturers of waterjet cutters will train you on how to use their machines.

As an example, SAME Waterjet offers lifetime technical support and training for their waterjet cutting machines. They have trainers available to provide one-on-one training so that you can properly and safely use the machine.

Support is often provided by the manufacturer of the waterjet cutter – both on-site and over the phone. They should have a team of technicians available to troubleshoot and fix any issues that may arise with the machine.

It’s important to have a good relationship with the manufacturer and to keep up with regular maintenance to minimize potential breakdowns. Also, having warranty coverage can provide peace of mind in case something does go wrong with the machine.

This will depend on the specific manufacturer and their policies. Some may offer on-site technicians, while others may only offer remote support. It’s important to inquire about this before purchasing a waterjet cutter and to have a plan in place for any potential breakdowns or maintenance needs.

For example, SAME Waterjet provides comprehensive support for all of its customers. They have rapid on-site support to help you connect with an experienced technical support team member as well as over-the-phone support. In addition, they have local services in Asia, the United States, Australia, and Europe.

Waterjet cutting technology has revolutionized many industries and can be a great asset for your business. Using this technology in your business can greatly improve productivity and efficiency.

A waterjet cutter offers the best of both worlds — precision and flexibility. It can open up new opportunities for diversifying and expanding your business.

Furthermore, Water jet cutting is less expensive than traditional methods. It’s a complete process, meaning no second cuts or finishes are needed. The absence of heat also means that materials maintain their integrity and strength, so there is no waste.