Waterjet cutting at DeSta::Microcut

Micro waterjet cutting is a high-precision cutting process with a cutting accuracy of up to ±0.01 mm. DeSta::Microcut processes workpieces with material thicknesses of 0.05 to 40.00 mm and maximum dimensions of 2,000 x 1,000 mm. The technology is characterized by minimal heat input and low impact on the material structure. This means that even materials that are sensitive to heat can be cut through. Waterjet cutting is ideal for the economical production of prototypes and series. More precise than conventional waterjet cutting, micro waterjet cutting at DeSta::Microcut is a high-quality alternative to laser precision cutting and wire erosion.

What is waterjet cutting?

Waterjet cutting uses a high-energy jet of water – also known as a waterjet – to cut through materials. DeSta generally uses the abrasive waterjet cutting process. The water is put under high pressure and mixed with an abrasive. The resulting jet is able to cut through almost any material, as the abrasive significantly increases the cutting force of the jet. Even very hard materials such as ceramics or sintered carbide can be cut precisely in this way.

An alternative process for soft materials is pure water jet cutting, in which only water is used.

We are happy to support you!

The experienced team at DeSta::Microcut is ready to support you with your individual challenges. Whether you have specific requirements for prototypes or small series, the team is at your disposal with years of expertise and know-how. The aim of DeSta::Microcut is to offer you the best possible service.

Overview of materials & typical materials

The abrasive waterjet cutting used at DeSta::Microcut is able to cut through materials with high precision and virtually burr-free. The variety of common materials that can be cut with high precision and quality using waterjet cutting is considerable. An overview:

Metals and metal alloys

Steel and steel alloys such as structural steel, stainless steel, tool steel, case-hardening steel, spring steel, CNS alloys
Non-ferrous metals such as copper and copper alloys, brass, bronze
Precious metals such as gold, silver, platinum
High-temperature alloys based on iridium, rhodium, tungsten
Other non-ferrous metals such as aluminum, magnesium, nickel, tantalum, tin, zinc, titanium, Inconel (nickel-based alloys)
Solid carbides, bi-metals and structural materials

Plastics

Thermoplastics: polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET)
Thermosets: phenolic resin, melamine resin, epoxy resin, urea resin, polyester resin, diallyl phthalate (DAP), silicone resin
Elastomers: polyurethane (PU), rubber
Polymethyl methacrylate - PMMA ("Plexiglas"): Altuglas, Oroglas, Lucite
Foams such as flexible foams, rigid foams, insulation materials, Forex® (PVC rigid foam boards)
Friction elements such as PTFE, coated materials
Sealing materials such as silicone, rubber, natural rubber
Other: Polychloroprene (neoprene), silicones

Fiber composites

Non-metallic inorganic materials

There are many applications in which waterjet cutting of steel is the most economical solution while at the same time meeting high precision requirements.

Common raw materials are usually in stock at DeSta::Microcut’s raw material warehouse. This means that extremely short delivery times are also possible.

Do you need processing with a precise and gentle cut and your material is not listed here?

The advantages of waterjet cutting in detail:

Versatility: One of the biggest advantages of the process is its flexibility, as waterjet cutting cuts cleanly through almost any material. The spectrum ranges from metals and plastics to ceramics and natural stone.
Precision: The process also allows complex contours and shapes to be cut with high repeat accuracy.
"Cold" process: Waterjet cutting generates little heat input, which means that thermal influences are usually negligible. This is a decisive advantage, especially for heat-sensitive materials, as the material does not undergo any structural changes, hardening or discoloration. DeSta::Microcut can therefore also offer waterjet cutting of Nitinol for medical applications.
Clean cuts: The cut edges are clean and virtually burr-free. This often means that no further post-processing is required.
Cost efficiency and environmental friendliness: The cold cutting process produces neither harmful vapors nor gases. The noise and dust pollution is low compared to other common processes. The cutting technology is an efficient solution for many materials and material thicknesses.

The main disadvantages of waterjet cutting are

Lower feed rate compared to laser cutting: The cutting speed of the water jet is lower in comparison.
Limited suitability for very thin materials: If the material is too thin (<0.05 mm), it cannot be waterjet cut.
Wear: The addition of the abrasive causes wear to all blasting components, e.g. the cutting nozzles.
Cost of abrasive: The amount of abrasive added increases when cutting hard materials. This can increase wear and costs.
Moisture: The workpieces get wet during cutting. The process is therefore only suitable to a limited extent for some electronic components.

DeSta::Microcut has many years of expertise in waterjet cutting. Among other things, the choice of the right abrasive depending on the material to be processed plays a decisive role in minimizing the environmental impact and keeping costs as low as possible.

What are the advantages and disadvantages of waterjet cutting compared to other cutting processes?

Waterjet cutting is a universally applicable process that cuts through the material gently.

Exchange

DeSta::Microcut manufactures individual workpieces. The basis for this is created by the employees together with customers through personal consultation and exchange at eye level to jointly solve individual challenges.

Flexibility

A wide selection of raw materials in stock and the adaptive use of resources enable short-term deliveries and a high degree of flexibility in production.

Creativity

Driven by the curiosity to solve difficult challenges, the DeSta::Microcut team meets your individual requirements with courage, creativity and problem-solving expertise.

Reliability

At DeSta::Microcut, experienced specialists, modern machines and years of know-how guarantee the punctual production of high-quality workpieces.

System quality: The quality of the waterjet cutting system itself, as well as the selection and condition of the components, have a significant influence on the accuracy achieved.
Material hardness: Cutting very hard or very soft materials can impair precision.
Material thickness: Thinner materials can usually be cut with tighter tolerances.
Know-how: The knowledge and experience of our employees enables us to explore the physical and technical limits.

DeSta::Microcut cuts material thicknesses from 0.05 mm to 40.00 mm. Waterjet cutting has an accuracy of up to ±0.01 mm depending on the material and material thickness.

Do you have specific questions about precision and tolerances for your production project with demanding materials?

How precise is waterjet cutting?

Waterjet cutting is a very precise cutting technique and is therefore used in many industries as a proven and material-friendly process. DeSta::Microcut achieves an accuracy of up to ±0.01mm. The exact tolerances depend on several factors, including

Application examples for waterjet cutting

Waterjet cutting is a versatile technology and suitable for a wide range of materials and applications. The specific area of application depends on the type of waterjet.

Water jet with abrasive

Hard materials such as steel, stainless steel, non-ferrous metals, ceramics, glass, granite and plastics.
Large material thicknesses: Even cutting thick materials up to 40.00 mm is no problem for DeSta::Microcut.
Temperature-sensitive materials: As cold cutting and low heat input are used, the process is particularly suitable for heat-sensitive materials.
Complex shapes: Precise cutting of complex contours and shapes is possible thanks to the fine water jet.

Pure water jet

Which industries benefit from waterjet cutting?

Waterjet cutting is a very versatile process and enables precise and gentle cutting of almost any material of varying hardness and thickness. The process is therefore used in a wide range of sectors, from industrial applications to artistic project planning.

Applications for waterjet-cut components can be found across all industries, for example…

Do you have a special application? Just ask us!

We process metal workpieces for the following industries:

Automotive industry: Prototypes for brackets, pins, plugs, conductors; prototypes and spare parts for gearboxes after the end of series production.
Fuel cells & other alternative drives: Bipolar plates and end plates for fuel cells
Electric drives & Storage systems: Rotor and stator for electric motors, cell connectors, conductors and busbars for storage systems
Medical technology: Blanks for knives, saws and scalpels; components for medical devices; blanks for implants and bone holders; Nitinol templates for surgery
Mechanical components & connections: Leaf springs, pins, press-fits.

Aerospace: Thermal & heat protection elements such as heat protection plates; Electrical systems such as power connectors; Mechanical components e.g. spoke springs, friction elements; Fastening & assembly, e.g. brackets, retaining rings, locking pieces, gauges and material science, e.g. tensile tests for material testing
Mechanical engineering: Production of various precision parts for systems and machine components, e.g. spacer plates, brackets
Jewelry & optics: Cutting eyeglass frames, jewelry pendants and watch dials
Stamping industry: Cut prototypes and pre-series for the development of stamped parts, also bent, milled and/or laser-marked on request; wear plates and spacer plates for tools; series production for small and medium series as well as spare parts after discontinuation of series production

We process composite materials for the following industries:

We process electronic components for the following industries:

Electronics industry: Cutting of printed circuit boards (including ceramic), semiconductor and chip components such as chip carriers, complex chipsets, multilayer electrical chips, copper semiconductors
Electrical connection elements: Circuit boards, carbon shafts
Power transmission and distribution: Busbars, conductor rails, contacts, contact rails, cable lugs, crimp contacts (plugs)
Sensors and actuators: Sensors, piezo-ceramics, pulse disks

Glass, textiles and other materials can be processed for (not in the DeSta::Microcut portfolio):

Construction industry: Cutting of natural stone or granite for floors, facades and worktops
Glass industry: Cutting glass for windows, mirrors and custom-made products.
Arts and crafts: Production of sculptures and works of art
Food industry: Food such as meat, cheese and cakes are hygienically cut
Textile industry: Technical textiles and membranes can be cut cleanly

What material thicknesses can be processed with waterjet cutting?

The material thickness that can be processed with a waterjet cutter depends, among other things, on the type of waterjet, the material used and the desired cutting quality. The abrasive waterjet cutting used by DeSta::Microcut allows material thicknesses of 0.05 mm to 40.00 mm to be cut. Greater material thicknesses require longer cutting times.

Do you have questions about the suitability of waterjet cutting for your project?

Are there any restrictions on the choice of material for waterjet cutting?

Waterjet cutting is a versatile cutting process that can be used to cut almost any material. However, there are some limitations to the choice of materials, including

Pure waterjet cutting vs. abrasive waterjet cutting

In pure waterjet cutting, the force of the thin jet of water emerging under high pressure through a nozzle produces the cutting effect. This is different with abrasive waterjet cutting. Added abrasive particles accelerate in the water jet and have a significant effect on the cutting process. The choice of abrasive is decisive for the result, depending on the material and material thickness.

Pure waterjet cutting is particularly suitable for the precise cutting of soft materials. Suitable materials include foams, rubber and thin plastics.

Abrasive waterjet cutting makes it possible to cut much harder materials by adding an abrasive such as garnet sand. The abrasive makes a significant contribution to the cutting process and abrades the material in a similar way to a grinding wheel. This makes it possible to cut through steel, stone, glass, ceramics or tiles with waterjet cutting.

What components does a water jetting system consist of?

The principle of the cutting technology is based on the following components:

High-pressure pump: A pump is used to generate a high pressure of several thousand bar for waterjet cutting.
Abrasive supply: The quantity of abrasive added is precisely dosed via a dosing device.
Mixing chamber: This is where the abrasive and water are evenly mixed.
Nozzle: The nozzle with the required diameter concentrates the water jet.
Material pick-up: The material to be cut is precisely aligned and secured.
CNC control: The movement of the cutting head is precisely controlled by the machine based on the CAD data and the cutting strategy.

Factors influencing tolerances and precision in waterjet cutting

Waterjet cutting is a high-precision cutting process. DeSta::Microcut uses abrasive waterjet cutting and achieves a cutting accuracy of up to ±0.01 mm depending on the material and material thickness. The achievable tolerances depend on these factors, among others:

Cutting speed: Higher speeds can result in greater tolerances.
Machine type and precision: Modern machines and regularly maintained components achieve better results.
Abrasive additive: Tighter tolerances are generally possible with abrasive waterjet cutting than with pure waterjet cutting.
Material: The behavior of different materials varies during waterjet cutting.
Material thickness: Thicker material results in greater tolerances.

Is waterjet cutting suitable for prototypes and small series?

Waterjet cutting is ideal for prototypes and small series. In addition to the fundamental advantages of the cutting process, the following are particularly important:

Cost-effective: There are no one-off tool costs. This means that waterjet cutting is often a technically and economically optimal solution for small batches.
Fast iteration: Design changes can be quickly implemented in new prototypes thanks to the CAD/CAM connection and maximum precision.
Complex geometries: Complex shapes and contours can be cut precisely. This is a significant advantage, especially for innovative prototypes.

What surface quality is achieved with waterjet cutting?

Waterjet cutting achieves high-precision, smooth and virtually burr-free cuts and therefore low surface roughness. The fine surface finish is a key criterion for applications in industries with strict surface quality requirements, for example to meet specific safety requirements or to ensure a high level of aesthetics.

The reason for the low surface roughness is the lack of an aggressive shearing effect, as is the case with machining processes, for example. This protects the material from micro-cracks and stresses. In addition, no high temperatures are generated during cutting. Thermal damage to the workpiece can therefore be reliably avoided.

In addition to waterjet cutting, DeSta::Microcut also has these machining options in its portfolio as a comprehensive provider of machining processes in manufacturing:

DeSta::Microcut’s range of services also includes a number of post-processing options. These include

Through its sister company BLS Lasertechnology GmbH, DeSta::Microcut also offers high-quality laser material processing of 3D parts. BLS Lasertechnology GmbH has all essential processes for the laser processing of 3D metal components in its portfolio.

What processing options does DeSta::Microcut offer in addition to waterjet cutting?

What else should I know about waterjet cutting at DeSta::Microcut?

DeSta::Microcut is your service provider for micro waterjet cutting and laser precision cutting. With many years of experience and extensive know-how, the team ensures the reliable production of precision workpieces in high quality and prides itself on its ability to find the technically and economically optimal solution for complex challenges. DeSta::Microcut also offers you a wide range of downstream processes such as milling, bending, laser marking and surface finishing.

Would you also like to benefit from the expertise and performance of DeSta::Microcut?