Defining Precision:

Revolutionary Abrasive Waterjet Technology

Presented by
Walter Siegenthaler
Executive Vice President
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WATER JET CUTTING FOR
MICRO AND HIGH PRECISION PARTS
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Today’s Topics:
• Comparing conventional cutting methods
• Avoiding heat affected zones
• Abrasive Waterjet process/ technology
• Solutions using collaboration of processes
• Selecting the right material
• The future of precision abrasive water jet cutting
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Comparing traditional cutting methods:

• Wire EDM
• Conventional Laser Cutting
• Waterjet Cutting
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Shameless Disclaimer…
•The specifications stated in this presentation
are averages based on my own research of
information provided by various
manufacturers and service providers.
•You may have seen or experienced different
data yourself.
•Please feel free to speak with me after the
presentation.
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Wire EDM advantages:

• Extremely accurate process
• Able to cut multiple parts in a “stack”
• No burr on cutting edge
• Virtually no edge taper
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Wire EDM disadvantages:

• Cutting process is slow as compared to other processes
• Leaves heat affected zones in material
• Leaves recast layer on material
• Non-conductive materials can not be cut using EDM
• Large quantity production is cost effective, prototypes
are expensive to produce
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Conventional Laser Cutting advantages:

• Fast cutting speeds
• Accurate beam positioning
• Beam width (kerf)
• No “wear” on the beam - consistent results
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Conventional Laser Cutting disadvantages:

•Stacking material is not practical
•Leaves heat affected zones in material
•Leaves recast layer on material
•Some materials are not compatible
•Can be a high consumer of energy
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Heat Affected Zones may cause problems …

•Additional processes such as heat treating may have to be
performed to reverse the HAZ
•Materials such as spring steel will have changed molecular
structure
•Material may show cracking in these areas
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Conventional Abrasive Water Jet characteristics:

•Mechanical Energy
•Parts Accuracy 0.1mm
•Minimum Inside Radius 0.4mm
•Minimum Hole Diameter 0.8mm
•Kerf width 0.8mm (few now as low as 0.5mm)
•Thickness Range 5mm to ~ 300mm
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Conventional Abrasive Water Jet advantages:

•Fast cutting speeds
•Capable of cutting thick material
•Roughing process for milling
•No Heat Affected Zones
•No recast layer
•Virtually any material can be cut using AWJ
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Conventional Abrasive Water Jet disadvantages:

•Thicker material often shows taper
•Wet process – problematic to some materials
•Often only usable as roughing process
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Micro WaterJet characteristics: Conventional AWJ:

•Mechanical Energy •Same
•Parts Accuracy 0.01mm •0.1mm
•Minimum Inside Radius 0.15mm •0.4mm
•Minimum Hole Diameter 0.30mm •0.8mm
•Kerf width 0.3mm AWJ •0.8mm (few now 0.5)
•Kerf width 0.08mm WJ •0.25mm
•Thickness Range 0.01mm to ~100mm •5 mm up to 300 mm
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collimation tube
L_kol

D_kol

al

orifice
ph
a

D_abr
a_abr

c
L_mix

D_mix
D_cone
b
abrasive connection
L_cone

mixing chamber
head body

focusing tube
Da_foc
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• Take advantage of the resources available to you…

• Use multiple processes to increase precision of your part,
reduce waste and handle the product as little as possible.
Defining Precision

• Take advantage of the resources available to you…

• Use multiple processes to increase precision of your part,
reduce waste and handle the product as little as possible.
Defining Precision

• Take advantage of the resources available to you…

• Use multiple processes to increase precision of your part,
reduce waste and handle the product as little as possible.
Defining Precision

• Take advantage of the resources available to you…

• Use multiple processes to increase precision of your part,
reduce waste and handle the product as little as possible.
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Select the right material for the right application…

•During the design stage, be aware of how your material can be
processed for production
•Create a partnership with a contract manufacturer who will work
closely with you and is willing to advise during design changes
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Ceramic (0.25 mm wide slice) 7mm thick work piece
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PTFE
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Neoprene
20 mm
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Delrin
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Phenolic
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Carbon steel
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Stainless Steel
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Titanium
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Hyperco 50
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Nitinol
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Spring Steel
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Sterling Silver
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Plans for advances in Micro Waterjet technology:

• Reducing the kerf from 0.3mm to 0.2mm (2010)
• Reducing the kerf to 0.1mm
• Tilt head with same precision
• Addition of a rotary axis for cutting parts in the round
• With this, the addition of 3-Dimensional CNC software will
be a necessity
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Thank you for your time and

attention!