Laser cutting technology works by generating a high-powered beam of laser at the material to be cut, while waterjet cutting technology uses a high-pressure jet of water combined with abrasive particles to cut through the material. 

So which one is better, laser cutting vs waterjet cutting? Well, it depends.

Our goal today is to analyze the pros and cons of each approach to understand the most appropriate applications for these technologies. 

We will examine their working process, material compatibility, safety features, cost, accuracy, and other important factors to help you better understand each process.

So, let’s explore further!

Laser Cutting VS Waterjet Cutting: Overview

Before delving further into this topic, it is important to understand the specific functions of each machine. Although their main purpose is to cut material, their operational methods are undoubtedly very different from each other.

What is Laser Cutting?

The first laser cutting machine appeared in 1965, primarily for drilling holes in diamond dies. However, it was not until the 1970s that these tools gained prominence in aerospace applications, where they proved effective in cutting through titanium.

Laser cutting technology works by generating a high-intensity laser beam, which is then guided onto the material by laser optics and CNC (computer numerical control). This extremely narrow and focused beam can melt, burn or vaporize the material, resulting in a perfectly cut edge.

Different Types of Laser Cutting

When it comes to laser cutting, the laser beam is the primary source of heat for cutting the material, and it can be created in different ways and with different power ranges. Thus, this process can be classified into three categories, each capable of handling different material types and thicknesses.

CO2 Laser Cutting: Carbon dioxide gas in a sealed glass tube is electrically stimulated to produce a laser beam with a wavelength of 10.6 micrometers. Perfect for cutting materials such as plastic, wood, rubber, and paper.

Fiber Laser Cutting: It uses rare earth-doped elements such as erbium to produce a laser beam through an optical fiber with a wavelength of 1.064 micrometres. Perfect for precise metal or plastic cutting, etching, and engraving.

Diode Laser Cutting: Uses crystals such as Nd:YVO and Nd:YAG to produce a beam with a wavelength between 550 nm to 950 nm. Perfect for cutting delicate fabrics, some ceramics, engraving wood, and etching certain acrylics.

Where is Laser Cutting Used?

Initially used only for cutting titanium in the aerospace sector, laser cutting technology has evolved significantly and expanded its reach. Today, it is widely used in a variety of industries, including the electronics, medical, automotive, and semiconductor sectors.

Additionally, laser cutters have emerged as an essential tool for educational institutions, small businesses, architectural practices, and hobbyists. Their primary function involves precision cutting of metals such as steel and aluminium.

What is Waterjet Cutting?

Compared to the history of laser cutting, waterjet cutting technology initially emerged as an industrial cutting tool in the 1930s, first used primarily by paper mills to cut large quantities of paper sheets. It was only during the 1970s that waterjet cutters found their way into the commercial sector as well.

Waterjet cutting works quite differently from laser cutting. In this process, water acts as the main element of the machine and is subjected to very high pressure (reaching 90,000 PSI). Then, it is combined with an abrasive material and directed through a narrow nozzle at the material to be cut.

Different Types of Waterjet Cutting

Depending on the type and thickness of the material you are looking to cut, the waterjet cutting process can be divided into two distinct categories – pure waterjet cutting and abrasive waterjet cutting.

Pure Water Jet Cutting: This method uses only high-pressure water to cut soft materials such as rubber, foam, and paper.

Abrasive Waterjet Cutting: In this method, an abrasive such as garnet is added to the water stream to increase its strength and cut harder materials like steel.

Where is Waterjet Cutting Used?

The versatility and flexibility of waterjet cutting make it a preferred choice for machine part fabrication in several industries. Its ability to operate with zero margins for error and handle heat-sensitive materials sets it apart. Key industries including aerospace, automotive, medical, and food processing use this technique to accurately cut, shape, and design parts.

Laser Cutting VS Waterjet Cutting: How Are They Different?

After gaining a basic understanding of waterjet laser cutting technologies, including their basic types and applications, now it’s time to further explore one by one the key differences that separate laser cutting vs waterjet cutting.

Working Process

A key difference between waterjet and laser cutting lies in their individual working methods. Laser cutting involves the use of a focused laser beam, while waterjet cutting relies on a strong stream of water mixed with abrasive particles to perform the cutting process. Let’s understand it step by step.

Working of Laser Cutter

Step 1: The laser cutting process begins with generating a laser beam. It is produced by stimulating a medium such as a gas or crystal using an external energy source.

Step 2: Then, multiple mirrors within the machine direct the beam to the laser head, where it travels through a lens that focuses the beam to a specific point.

Step 3: As the focused laser beam interacts with the material being cut, sufficient heat is generated, causing the material in the incision area to melt, vaporize, or burn.

Working of Waterjet Cutter

Step 1: The water jet cutting process begins with creating a high-pressure water stream. The water is pressurized using a pump to reach pressures of 30,000 to 90,000 PSI.

Step 2: This pressurized water is then directed to the cutting head using high-pressure tubing. Here it passes through a small orifice which focuses the water into a thin beam.

Step 3: There is an option to mix the abrasive with water in a mixing tube near the cutting head. Then, high-velocity water or abrasive waterjet exits the nozzle and cuts the material.

Material Compatibility

Of course, material compatibility serves as a key difference between laser cutting and waterjet cutting. If a particular technology cannot cut the desired material, its other advantages become irrelevant, making it unsuitable for use.

Both laser and waterjet cutters can work with a wide range of materials. Nevertheless, due to waterjet cutting’s use of pressurized water and abrasives, it can effectively cut almost all known materials, such as metals, composites, plastics, rubber, and many natural materials.

On the other hand, laser cutting is suitable for materials like plastics, wood, and metals. It is best with materials that do not have heat transfer problems and require etching or engraving without full cutting. However, cutting reflective and highly heat-sensitive materials can pose challenges.

Speed and Accuracy

In terms of speed and accuracy, laser cutting generally has an advantage. Laser cutters can cut material faster than water jet cutters, making them ideal for mass production runs.

With cutting rates between 20-70 inches per minute, laser cutting outperforms water jet cutting, which tops out at 1-20 inches per minute.

Moreover, laser cutters provide great precision with the ability to cut with an accuracy of 0.01mm and down to 0.005mm. On the other hand, the water jet only has a cutting accuracy of 0.13mm and down to 0.025mm.

Material Thickness

The erosion technique used in waterjet cutting places virtually no restrictions on the thickness of the material that can be cut.

Laser cutting is a cost-effective option for cutting steel or aluminium sheets with a thickness of up to 12mm, while water jets can handle any thickness.

For reference, water jets can easily be cut up to 150mm in hard materials. Although it is possible to cut even thicker material, additional time must be considered.

Laser Cutter Advantages Over Waterjet Cutter

Laser cutting offers many unique advantages over water jet cutting. Here’s a look at some of the most notable benefits that come with integrating a laser cutter into your operations:

High-Quality Cut

This machine cuts materials with great precision and fine detail thanks to a positioning accuracy of 0.01 mm to 0.005 mm. Ideal for industries that require tight tolerance levels.

Best Cutting Speed 

Laser cutting is considerably faster than water jet cutting, typically operating at speeds of 20-70 inches per minute. This increased speed makes the process more productive.

Use Less Energy

Despite the need for significant power to cut efficiently, laser cutting has low power consumption due to the lack of moving parts, high efficiency, and high cutting speed.

Much Quieter 

The noise level produced during water jet cutting is so high that ear protection is required, unlike laser cutting, it is a quiet process with the machines producing only 75 dB of sound.

Less Waste

Laser cutting produces minimal waste as only a small amount of material is lost during the process. This results in less solid and liquid waste and greater utilization of materials.

Waterjet Cutter Advantages Over Laser Cutter

The versatility of waterjet technology and the cold-cutting process have attracted the attention of several industries. Additionally, it offers some unique advantages that make it the preferred option over laser cutters. Here are some of the benefits:

Environment Friendly

With no heat-affected zone, toxic fumes, or dust particles and the ability to recycle water, waterjet cutting is a sustainable and environmentally friendly option.

No Thickness Limit

Thickness is not an issue when it comes to waterjet. It can easily cut materials up to 25-30 cm (10-12 inches) thick. However, the thicker the material, the longer it may take to cut.

Recycling Capabilities

Water used during the cutting process is not wasted. It is consumed during the cutting process, drained, and then reused over and over again, making it a sustainable option.

Risk-Free Process

Compared to laser machines that emit a lot of heat and can ignite nearby items, waterjet cutting is a safer option because it works by cold cutting, eliminating the risk of fire.

No Secondary Finishing 

Imperfect cuts may require secondary finishing, but the exceptional edge quality and clean, smooth cuts achieved by waterjet cutting usually negate the need for such finishing.

Which Material is Best For Waterjet Cutting

Waterjet has the edge over laser cutting in terms of material versatility, easily handling up to 12 inches of any material. Here are some of the materials and types that can be cut using waterjet technology.

Metals

From titanium, aluminium, stainless steel, and copper to all other exotic metals, they can all be cut with a waterjet.

Natural

Whether you need to cut glass, wood, marble, or leather, water jets are capable of cutting them with precision.

Composites

Carbon fiber, fiberglass, and other composites can be cut without problems using waterjet technology.

Plastics and Rubber

Waterjet is suitable for cutting plastics, foam, polycarbonate, and PVC, as well as rubber and silicone materials.

Note: When it comes to waterjet cutting, diamond, and tempered glass are not ideal materials. This is because diamond is incredibly hard, while tempered glass is prone to breaking when exposed to high stress.

Which Material is Best for Laser Cutting

Laser-cutting machines are versatile and capable of handling a variety of materials, but some materials are better suited to cutting, engraving, and marking than others. The following is a list of materials that are compatible with the laser cutter.

Metals 

Laser cutting can efficiently cut stainless steel, mild steel, and non-ferrous metals up to 30 mm thick.

Wood 

Various types of wood, such as plywood and MDF, can be cut with precision using laser cutting techniques.

Paper & Cardboard 

Laser technology is perfect for cutting, engraving or perforating the paper, cardboard, and pasteboard.

Plastics & Rubber 

Laser cutting can handle a variety of plastics, including acrylic, fluoropolymers, polyester, as well as rubber.

Note: The following materials should be avoided for laser cutting: PVC, ABS, fiberglass, carbon fiber, and polypropylene foam. These materials can emit harmful gases and fumes and are a fire hazard.

Waterjet vs Laser Cutting Cost

When comparing the costs of waterjet cutting vs laser cutting, it is important to avoid making decisions based on any one factor. To truly understand the costs associated with each technology, we need to consider the upfront cost of the machine plus component costs and operating costs.

So, let’s examine these costs separately to get a clear picture.

Machine Cost:

When comparing the upfront costs of laser and waterjet machines of the same capabilities, a waterjet machine usually costs significantly less than a CNC laser. The cost depends on factors such as machine type, available features, machine size, and material properties of the workpiece you plan to cut.

CO2 laser cutters typically range from $2,000 to $1,000,000, while fiber laser cutters can cost anywhere from $30,000 to $600,000. For waterjet machines, starter prices are around $30,000-$60,000, with higher-end models ranging from $60,000-$250,000.

Operating Cost:

Laser cutting machines are a more cost-effective option with operating costs of $13-$20 per hour, compared to water jets at $15-$30 per hour. The abrasives required for waterjet cutting make its operating costs slightly higher than laser cutting.

Components Cost:

The cost of consumables, such as abrasives, and the frequent wear and tear of components such as nozzles, high-pressure plumbing, and seals, make waterjet cutting more expensive than laser cutting. On the other hand, higher demand for laser cutting results in lower component costs than water jet cutting.

Laser Cutting VS Waterjet Cutting: Alternative

While both waterjet and laser cutting technologies have their strengths, it is important to note that they are not the only options available for metal cutting.

In fact, there are several alternatives that are highly sought after and can provide equally effective solutions. Here are two of the best:

Plasma Cutting

Plasma cutting is a thermal cutting process that uses a high-voltage electrical arc to heat and ionize the gas, producing an intense and focused jet of hot plasma. 

The plasma effectively melts through the metal, while high-velocity gases simultaneously blow away the molten material, leaving a smooth cut in the workpiece.

The cost of plasma cutting is affected by a few different factors, such as system size, power capacity, and any special features included. 

Also, it is worth noting that plasma cutters are designed to work only with electrically conductive materials so that the necessary electrical contact between the torch and the raw material can be established.

Pro Tip: Also check out our detailed guide on waterjet vs plasma cutting.

EDM Cutting

EDM cutting is a process that removes material from conductive materials using electric sparks. An electrode and the workpiece are connected to the power supply.

This creates a voltage difference between them that causes electrical discharges (sparks) to jump between the electrode and the workpiece and melt the material.

Compared to other cutting technologies, EDM has the ability to cut material up to 12 inches thick and work with more precise tolerances down to 0.0001”.

Laser Cutting VS Waterjet Cutting Safety

In terms of safety between these two cutting technologies, water jet cutting has proven to be the best option over laser cutting. While both methods have their strengths, waterjet cutting stands out for its exceptional safety features and reduced risk factors.

Here are some safety benefits that come with waterjet technology:

1. No Heat Generated:

Waterjet is a cold-cutting process that eliminates the risk of heat-related distortion, warping or material weakening because no heat-affected zone is formed.

2. No Hazardous Fumes:

When working with hazardous or sensitive materials, waterjet cutting is a safe option because it produces no toxic fumes or gases, regardless of the material being cut.

3. Reduced Fire Hazard:

Due to the absence of heat generation during the waterjet cutting process, the risk of fire or combustion with nearby materials is significantly reduced.

4. No Dust or Debris

Waterjet cutting machines are equipped with a waterbed that ensures that any debris or dust generated during the cutting process is captured immediately.

Because of the high level of heat and radiation involved, laser cutters, unfortunately, do not offer the same safety benefits as waterjets. As a result, certain risks may arise when operating a CNC laser cutter, such as:

1. Fire Hazard

Laser cutting in an area where oxygen is abundant can cause frequent fire hazards. Also, if flammable materials are located near the laser, they can absorb heat and potentially start a fire.

2. Gas Hazards

Laser cutting can produce gases or fumes as a result of burning and vaporizing the material, which can produce unpleasant odors. Moreover, some of these gases can be toxic if inhaled.

3. Skin Hazard

Precautions must be taken when using a laser cutter as it can cause serious skin damage, including burns, eye damage, and skin irritation from direct exposure to the laser beam.

Laser Cutting VS Waterjet Cutting: Which is Better?

Deciding whether to choose a waterjet or laser cutter is a decision we can’t make for you. Ultimately, the choice depends on your personal preferences, budget constraints, and the application or requirements of your project.

To summarize the key differences between these technologies that we have discussed above, if you handle a variety of materials or thick sheets and prefer an environmentally friendly approach to cut them, waterjet is the best choice.

However, if you prioritize speed, reasonable accuracy and cost efficiency when it comes to cutting or engraving materials, a laser cutter is definitely worth your consideration.

Conclusion

As we wrap up our discussion, it becomes clear that no single cutting technology can meet all situations. Both laser and waterjet cutting offer distinct advantages and capabilities.

The ideal choice between these two technologies ultimately depends on factors such as material type, project scope, budget, and desired end quality you require.

If you find yourself unsure about which method best suits your needs, don’t hesitate to contact us at IVYCNC. Our team of CNC industry-leading experts are ready to provide tailored guidance and help you find the best possible solution for your project.