Waterjet cutting is commonly used to produce two-dimensional gaskets from thicker and/or tougher materials. It is beneficial in a variety of scenarios, depending on the quantity of parts produced, the material utilised, the intricacy of your design, and the speed with which you need the components supplied. EMI Seals and Gaskets Ltd uses the most advanced technology available to cut nearly any product to accurate specifications utilising the power of Waterjet Cutting.
Water Jet Cutting Process and the technology behind it
Water jet cutting is a method of cutting through a variety of materials, including metal, plastic, rubber, and composites, using a high-pressure jet of water. A high-pressure pump pressurises water from 60,000 to 90,000 psi before passing it through a tiny aperture, generating an ultra fine, high-velocity jet of water.
The precision and accuracy of this technology are attributable to the employment of high-resolution cameras, sensors, and other advanced technologies that ensure the water jet follows the set course.
Since the water jet is so strong, it can cut through dense materials with exceptional precision while leaving a smooth and burr-free edge. This is accomplished by guiding the water jet with the use of a computer-aided design (CAD) tool that maps out the material’s cutting route.
Waterjet cutting for prototypes and production
As the requirement for rapid prototyping and custom gasket manufacturing has grown more widespread, the waterjet cutting systems from EMI Seals and Gaskets’ have helped us lead the industry in this area. These solutions not only serve to satisfy the demands of rapid prototyping, but they also allow for more precision and more intricate designs than steel rule cutting dies allow for. The ability to supply cut-to-size samples for rapid testing rather than generic material swatches gives you a competitive advantage. When material is available and the designer supplies transferrable CAD files, samples are often sent the same or following day.
The more complicated the gasket designs get, the higher the necessity for cutting equipment that can keep up with market demand. Waterjet devices catch up where traditional die cutting equipment loses off in terms of precision and capability. Waterjet devices deliver precision that die cutting cannot match. Many businesses have used EMI Seals & Gaskets’ waterjet cutting capabilities to satisfy their unique requirements when die cutting was not a possibility.
Advantages of using waterjet cutting for gasket production
Precision and accuracy
The water jet cutting procedure employs high-pressure water driven via a tiny nozzle. This results in highly clean and accurate cuts over a wide variety of material thicknesses. So, we normally recommend utilising water jet cut gaskets for intricate patterns and forms. It is especially appropriate for fragile or delicate textiles since the water jet puts less strain on the material. This guarantees that the gasket maintains its structural integrity while also allowing us to make clean cuts at all times.
Less stress on delicate materials
Gaskets are frequently composed of soft or sensitive materials that could be harmed by other techniques of cutting. Waterjet cutting, on the other hand, employs a high-pressure stream of water to cut the material, putting less stress on it and ensuring structural integrity.
Quick turnaround time
In comparison to other cutting procedures, we can make them rapidly. This allows us to produce prototype gaskets or small production runs in a reasonably short period of time. Because of the accuracy of the water jet, we can achieve better yields on average from a single sheet. This results in much less waste, saving you money and shortening lead times.
Higher yields and less waste
Waterjet cutting is also very efficient, allowing you to make multiple gaskets from a single sheet of material. This leads to reduced waste and greater yields, which could save you money and shorten lead times.
Eliminates stress fracturing and deformation
Water jet cutting is a very flexible procedure that can cut through a broad range of materials, including those that are difficult to manufacture using standard methods. Furthermore, because it is a cold cutting technique, there is no heat-affected zone (HAZ) that might deform or impair the structural integrity of the material being cut.
Waterjet cutting vs traditional cutting methods for gaskets
Water jet cutting provides various advantages in addition to its adaptability, precision, and accuracy. The water jet, for example, puts less strain on sensitive materials, making it an excellent choice for gasket manufacture. It is also a reasonably quick technique, allowing producers to develop prototype gaskets or limited production runs in a timely manner. Furthermore, water jet cutting generates substantially less waste, saving time, money, and resources.
|Criteria||Waterjet Cutting||Traditional Cutting Methods|
|Cutting Method||Uses High-pressure Water Stream||Uses blades or other cutting tools|
|Materials||Can cut through a wide range of materials, including soft or delicate materials||Limited to certain materials depending on the cutting tool used.|
|Precision and accuracy||Extremely precise with high accuracy and minimal material waste||Limited precision, with greater material waste and the potential for inaccuracies|
|Cutting Speed||Faster Cutting speed, with the ability to produce prototype gaskets or small production runs quickly||Slower cutting speed with longer lead times|
|Cost||Higher upfront cost due to the investment in specialised waterjet cutting equipment.||Lower upfront cost, but potentially higher material waste and longer production times, leading to higher overall costs.|
|Complexity||Ideal for complex designs and shapes, as it can easily manoeuvre around tight curves and angles||Limited flexibility for complex designs, with greater limitations on the shapes and sizes that can be produced.|
We utilise only pure water for the majority of the materials described on our website. However, abrasives could be applied to tougher substrates to increase cut quality and maintain ongoing cutting performance with minimum effort.
EMI Seals & Gaskets Ltd are able to offer a variety of cutting and manufacturing processes so that we can offer you the optimum solution for your requirements. If you would like to discuss a potential requirement or discuss an ongoing part please call EMI Seals & Gaskets Ltd at +44 (0)1590 688022 or fill out a contact form .