How Using an Industrial Water Cutter Can Revolutionize Aerospace Manufacturing

The aerospace industry is one of the most demanding when it comes to manufacturing. It’s a niche that requires precision, efficiency, speed, and customization for nearly every part. For that reason, a lot of modern aerospace companies are relying heavily on an industrial water cutter instead of traditional CNC machining.

In this guide, our machinists will explain why this is the case. We’ll outline what waterjet cutting is, why it’s great for aerospace companies, some common advantages it holds over CNC machining, and what types of parts you can use an industrial water cutter on.

What Is Waterjet Cutting?

Waterjet cutting is a manufacturing cutting process that uses high-pressure water to cut shapes out of sheet metal. The water is often mixed with small, abrasive materials to more consistently cut through metal.

While an industrial water cutter can be used to cut a wide variety of materials, it is almost exclusively used on metals within the aerospace industry. 

A waterjet cutter has a 2- or 3-axis gantry that controls the position of the cutting head. Material is loaded on a table directly underneath the head of the machine. From there, the head will shoot out pressurized water and move around, cutting external and internal shapes. 

Common waterjet cutters can only be used on flat pieces of metal, so the bending operation happens after the cutting operation.

Since these machines use water and not cutting tools, they don’t generate the additional heat that you would expect with CNC machines — this makes waterjet cutting one of the best options for working with temperature-sensitive materials.

Benefits of Waterjet Cutting in the Aerospace Industry

Why are a lot of modern companies turning to waterjet manufacturing for their aerospace projects? It boils down to an industrial water cutter’s impressive list of benefits:

#1 Versatility

Waterjet cutting's ability to slice through various aerospace materials makes it incredibly versatile. Plus, these machines run on 2D CAD files, which allows them to cut a limitless number of unique shapes and features.

A single waterjet machine can easily work on aluminum, titanium, and non-metallic materials. This is a huge advantage for aerospace companies that work with multiple different materials.

#2 Precision and Repeatability

With manufacturing accuracy of +/- 0.03 inches and the incorporation of CNC technology, waterjet cutting offers unparalleled precision. This repeatability is critical for aerospace components where every micron counts.

#3 Superior Surface Finish

Since waterjet cutters don’t use any cutting tools or rotating blades, they can achieve a much smoother surface finish during use. Aerospace companies often rely on surface finishes to help with air resistance and overall safety, so this is another big selling point.

#4 Complex Geometric Cutting

The complex geometries often required in aerospace parts, like wing truss structures, are perfectly suited to the capabilities of waterjet cutting. Advanced 5-axis waterjet machines can create incredibly complex parts in a fraction of the time.

#5 Small Batch Production Efficiency

For aerospace projects where production runs may be limited, waterjet cutting offers a cost-effective solution. Its fast operation and setup times result in lower costs, especially compared to methods like CNC milling machines.

#6 No Heat-Affected Zones

A significant advantage of waterjet cutting is its cold-cutting nature. Unlike plasma or laser cutting, an industrial water cutter does not create heat-affected zones (HAZ) — preserving the integrity and properties of the material.

Eco-Friendly Process

Waterjet cutting uses water as the primary cutting medium, making it an environmentally friendly process. At Rapid Axis, most of the water we use during a waterjet cutting project gets recycled and reused by the machine, further improving the process’ eco-friendliness.

Enhanced Durability

Parts manufactured through waterjet cutting exhibit high stress-bearing capabilities and enhanced durability, a necessity for aerospace components that endure high, cyclic loading. Plus, maintaining consistent edges with each cut helps with the longevity of each manufactured part.

Advantages of Waterjet Cutting Over CNC Milling Machines

While CNC milling is a cornerstone of aerospace manufacturing, waterjet cutting offers several advantages:

• More Affordable Option: Waterjet cutting is often more cost-effective than CNC machining, especially for complex parts.
• More Reliable: The process is less prone to the errors and limitations associated with CNC machining, particularly for materials sensitive to heat.
• Much Faster: For bulk manufacturing, using an industrial water cutter can significantly reduce production times.
• Tighter Tolerances at Lower Costs: Achieving tight tolerances is more economical with waterjet cutting, especially for intricate designs.

What Aerospace Parts Can Be Made with Waterjet Cutting?

As a whole, waterjet cutting has very few limitations when it comes to different parts that you can make. Speaking more specifically, a waterjet cutter can easily fabricate:

• Chassis/Body Panels: Perfect for creating standardized shapes with precision.
• Valve Components: Where high surface finish and accuracy are paramount for proper sealing.
• Polymer Insulators: Ideal for heat-sensitive materials that require a delicate touch.

Partner With Rapid Axis For Your Waterjet Cutting Projects

Waterjet cutting represents a leap forward in aerospace manufacturing — offering precision, versatility, and efficiency that other manufacturing options don’t. At Rapid Axis, our full-service machining capabilities includes an industrial water cutter. We can manufacture small or large batches of parts for your upcoming aerospace project. Contact us today to get a free quote.