As industries demand greater precision, efficiency, and customization in manufacturing, machinery has grown increasingly complex. Yet, some of the most effective technologies are rooted in the simplest principles. Our waterjet cutting system is a perfect example. It delivers high-performance results using one of nature’s most basic elements: water.
The Evolution of Waterjet Cutting
Early waterjet cutters were limited in both pressure and cutting duration. Today, modern waterjet systems regularly operate at pressures of 60,000 PSI or more. This exponential increase in cutting power allows for extremely precise fabrication of materials once considered too tough for such techniques. Despite the significant technological advancements, the core concept remains the same: harnessing pressurized water to cut through solid materials with unmatched accuracy.
Pure Water vs. Abrasive Waterjet Cutting
There are two primary types of waterjet cutting systems: pure water and abrasive waterjets. Abrasive models incorporate materials like garnet into the water stream to cut metals, stone, and other dense materials. We use a pure waterjet system, which is great for cutting open-cell and closed-cell foam materials such as polyurethane and polyethylene foam. While the machine is compatible with abrasives, they are unnecessary for the foam products currently fabricated here.
Benefits of Waterjet Cutting for Foam Fabrication
Unlike conventional saws, this method enables internal cuts without having to pierce the outer edges of the material. By simply stopping the water flow, repositioning the nozzle, and resuming the cut, our system can create enclosed shapes. This is perfect for components like gaskets, inserts, or casings that must maintain an uncut outer border.
Additionally, the CNC-driven (computer numerical control) interface allows waterjet cutters to function without the need for custom dies or molds. This makes waterjet cutting highly efficient for small production runs, custom projects, or rapid prototyping. When digital files are provided in advance, cuts can be programmed and completed within hours, which is dramatically faster than traditional methods that rely on tooling.
Unmatched Speed and Precision
Our waterjet system delivers precision down to 0.005 inches, which is just slightly thicker than a standard sheet of copy paper (0.004 inches). This fine stream allows for intricate patterns, clean curves, and sharp angles, all cut with consistency and repeatability that’s difficult to achieve by hand or with manual machinery. With a cutting surface of 10 feet by 7 feet, large sheets of foam can be processed with fewer setups and greater material yield, making high-efficiency cutting a standard practice.
How We Optimize the Process
While our waterjet cutter is capable of much higher pressure, we operate it at 45,000 PSI—roughly 75% of its maximum power—to reduce wear on materials and equipment. Foam sheets are supported by 7-inch-thick corrugated plastic blocks, which are modular and repositionable to extend their lifespan. Even at reduced pressure, the waterjet will eventually wear down these blocks. At a 40-hour workweek, the support blocks have a usable life of about one year. Learn more about our water jet foam cutting machine on our resource page.
A Modern Tool with a Timeless Principle
Waterjet cutting may rely on advanced machinery and precise programming, but the fundamental idea behind it is ancient: water shapes, cuts, and erodes. This timeless principle is transformed into a cutting-edge tool for accurate, clean, and efficient foam fabrication, demonstrating that innovation often begins with nature’s simplest ideas.
