Sheet metal fabricators typically use two processes: laser cutting and water jet cutting. However, these two processes are essentially different. But their applications in sheet metal cutting are intertwined. This is because manufacturers can derive additional advantages from the combination of the two. Therefore, deciding whether to use the water jet cutting or laser cutting process is not as simple as you might think.
The choice between laser cutting and water jet cutting can only be made after comparing the two. Therefore, this article will help you gain an insight into both the cutting methods. This article discusses the differences between water jet cutting and laser cutting. It includes the similarities between the two, their uses, and other methods you may use when cutting materials.
Table of Contents
Laser Cutting vs. Water Jet Cutting
What are laser cutting and water jet cutting processes
On the one hand, laser cutting uses a laser machine to emit a laser beam to cut material. The laser marking machine you choose determines the cutting process, power, efficiency, and compatibility. For example, fiber laser machines are strong and ideal for metals. CO2 lasers, on the other hand, are suitable for non-metals.
On the other hand, water jet cutting cuts materials by using a water jet machine to produce pressurized water. The water contains abrasives such as aluminum oxide and garnet that enhance the cutting ability. Due to its high concentration and speed, water jet machines can cut any material.
Explore the differences between the two
Are you unsure which cutting process is best for your project? Below is a general comparison of the two cutting processes. You can use this table to make an initial judgment as to whether they are suitable for your project.
| Waterjet cutting | Laser cutting | |
| Process | Involves cutting materials using high-speed abrasive-containing water | Involves cutting materials using a laser beam from a laser cutting machine |
| Material | Compatible with all materials | Compatible with all materials except some thermosensitive and reflective ones |
| Wall thickness | Can cut materials with thicknesses of 0.4” to 2.0” (10 to 50 mm) | Suitable for materials with thicknesses of about 0.12” to 0.4” (3 to 10 mm) |
| Tolerances | +/-0.005″ | +/- 0.002″ |
| Cutting speed | Not more than 20” thickness per minute  | About 70” thickness per minute |
Compatible Materials
In the comparison between laser cutting and water jet cutting. The type of material that can be cut is a key factor in determining which method is superior.
Laser cutting is suitable for a wide range of materials. For example, plastics, glass, wood, and metal. However, it is not suitable for cutting reflective materials. This is because reflective materials reflect the laser beam. In addition, laser cutting is not suitable for materials that are extremely thermally unstable.
On the other hand, the materials that can be cut with a laser are also machine-related. Therefore, you can ask your laser cutting service provider for information. And Yonglihao Machinery will be able to tell you which machine is best suited for your material. For example, most laser-cutting enthusiasts use CO2 laser cutters to cut organic materials.
In addition, water jet cutting has few limitations in terms of material compatibility. Unlike laser cutting, it does not generate heat. Therefore water jet cutting is suitable for cutting any material.
Wall Thicknesses That Can Be Achieved with Each Process
Laser cutting is the most cost-effective technique for cutting workpieces between 0.12 inches and 0.4 inches (3 to 10 mm) thick. However, the quality of the process depends on the material used. For example, laser cutting aluminum has a lower maximum thickness than carbon steel, which is more thermally stable.
On the other hand, water jet cutting has certain thickness limitations. This is because the technology is typically better suited for cutting thicker materials from 0.4 inches to 2.0 inches (10 mm to 50 mm). At lower thicknesses, the process is not useful. This is because the pressure of the water jet may cause damage to the workpiece.
Part Accuracy for Each Process
Laser cutting is more accurate than waterjet cutting. It has a minimum cut kerf size of 0.006 inches (0.15 mm). Waterjet cutting has a minimum cut kerf size of 0.02 inches (0.5 mm). In addition, the laser cutting process has a tolerance of approximately 0.002 inches (0.05 mm). The tolerance for waterjet cutting is approximately 0.008 inches (0.2 mm).
Cutting Speed for Each Process
Cutting speed is the thickness of material that can be cut per minute. Laser cutting has a higher cutting speed of approximately 70 inches per minute. Waterjet cutting speeds do not exceed 20 inches per minute. Therefore, laser cutting is more productive.
Similarities Between Laser Cutting and Waterjet Cutting
These two methods of cutting sheet metal may seem different, but there are some similarities. Here are a few similarities between laser cutting and waterjet cutting.
Versatility
Both the cutting processes are very versatile. As a result, many hobbyists are torn when it comes to making a choice. Both cutting processes are capable of working with a variety of materials. For example, steel, stainless steel, aluminum, copper, and bronze are some of the metal materials.
Small Kerf Width
The kerf width is the amount of material removed by the cutter in each cut. Both cutting processes have a narrow kerf width. Waterjet cutting has a kerf width between 0.7 mm and 1.02 mm. Laser cutting has a kerf width of 0.08 mm to 1 mm. Due to the narrow kerf widths, both processes are well suited for the construction of fine details and complex shapes.
High Quality
Both cutting processes produce high-quality cut parts. This is due to the precision and accuracy of the machinery used.
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Application Areas of the Laser Cutting Process
Laser cutting offers many advantages. The process produces products with extremely high precision, accuracy, and tolerances. In addition, they are highly cost-effective. Common application industries include the following:
Automotive Industry
Laser cutting is commonly used to cut automotive parts. Examples include chassis, hoods, roofs, and doors, as well as engraving car interiors. Since these parts are very robust, highly precise and accurate cutting techniques are required. In addition, laser cutting produces less scrap. Hence it is more cost effective and industry friendly.
Mold and Tooling Industry
Laser cutting has various applications in the mold and tooling industry. For example, its high tolerances and ability to cut materials of varying depths make it ideal for die casting molds. In addition, the laser cutting process is much more efficient. Hence, it is suitable for cutting high-strength metals.
Jewelry Industry
Laser cutting can be used to cut detailed designs on gold, silver, and diamond jewelry. Moreover, it can also be used for making jewelry. For the jewelry industry, laser cutting is the main cutting method. This is because it cuts with extreme precision and can handle small parts and narrow cuts, thus reducing material waste.
Medical Industry
Laser cutting can be used to cut medical device parts. Examples include stents, flap frames, flexible shafts, and hones. In addition, laser cutting can be used for laser surgery. This is because it allows doctors to perform precise surgeries. Medical device manufacturing companies prefer laser cutting because of its highly accurate cutting technology.
Electronics Industry
Circuit boards, wire stripping, customized appliance housings, and control panels are among the electrical components that are laser cut. This is because electronic components usually require tight tolerances, precision, and accuracy.
Areas of Application for the Water Jet Cutting Process
If the material to be cut is thick and thermally unstable. In addition, these parts require extremely high precision, accuracy, and tolerances. Then, water jet cutting is the best cutting process. This cutting process is widely used in the following two industries:
Automotive Industry
Waterjet cutting is commonly used to manufacture parts such as flanges, metal gaskets, skid plates, and customized bodies. The cutting process of this process does not create mechanical stress or heat-affected zones. Additionally, since these workpieces are thick, cutting with water jets is more efficient.
Aerospace Industry
Waterjet cutting can be used to manufacture components such as jet engines, turbine blades, and nacelle panels. Since waterjet cutting does not generate heat, it reduces small cracks and warping on the workpiece. Therefore water jet cutting is well suited for the aerospace industry.
Is Laser Cutting More Expensive than Water Jet Cutting?
If one wants to understand the cost difference between laser cutting and waterjet cutting. Then, first, you need to understand the cost of tools and parts as well as the operator and machine. Following is the cost comparison between waterjet cutting and laser cutting.
Tool and Parts Costs
Laser cutting has no tooling costs. The parts cost is also low due to the high requirements of the process.
On the other hand, waterjet cutting requires consumables and parts for proper machine maintenance. Therefore the parts cost for this process is high. Fortunately, waterjet cutting machines do not require tools.
Running Costs
Laser cutting typically costs between $13 and $20 per hour. Waterjet cutting costs between $15 and $30. Although the cost of both cutting processes is similar. However, if you are working on a large project, this can become critical.
For those who outsource their projects, cost is a very important consideration. Therefore, the operating costs of both sheet metal cutting processes should be taken into account when deciding whether to use waterjet or laser cutting.
Machine Costs
Water jet cutting machines cost less than laser cutting machines. Many laser cutting enthusiasts believe that purchasing the equipment is the most expensive part of the process. In addition to the initial cost of purchasing the equipment, the operating cost of laser cutting depends on the cost of electricity. If you are not outsourcing your project to a sheet metal cutting supplier. Then this is an important consideration.
Which is Better for Your Application, Laser Cutting or Waterjet Cutting?
The purpose of this article is not to decide which of these two cutting processes is better. Instead, this article is intended to help you make a decision by comparing the two cutting processes. In waterjet cutting vs. laser cutting, the cutting process that is right for your project is the best cutting process.
However, there are a number of factors to consider when deciding on a good strategy. Laser cutting is the best choice for jobs that require a high degree of precision and efficiency. Waterjet cutting, on the other hand, is suitable for thermally unstable materials and thicker materials.
Choosing the right cutting process for your project can be difficult. This is because you have to consider various criteria. Therefore, to increase efficiency, consider outsourcing to a sheet metal fabrication provider like Yonglihao Machinery.
Yonglihao Machinery has a team of experts experienced in waterjet cutting, laser cutting, and other sheet metal fabrication processes. As a result, you can increase efficiency while maintaining quality.
Yonglihao Machinery is an ISO 9001:2015 certified company. We have several manufacturing plants, advanced equipment, and precision machines. As a result, Yonglihao Machinery can help you with your project. By choosing us, you can save up to 30% on your order costs and get fast delivery.
Alternative Processes for Cutting Metal
Due to the need to meet productivity, efficacy, and other requirements, these two cutting processes may not be the best choice. Therefore, you may need to consider different options when discussing cutting metal. Plasma cutters and turret presses are two possible alternatives.
Plasma Cutting
Plasma cutting is differentiated from laser cutting. It is the process of cutting material with an ionized plasma jet at temperatures greater than 20,000°C. This method is suitable for some materials but can be used for many applications. This method is suitable for certain materials but is suitable for cutting steel and aluminum items.
This cutting process is known for its cost-effectiveness, accuracy, and cost. Additionally, plasma-cutting equipment is quite expensive at approximately $300,000 USD. However, their operating costs are lower than water jet or laser cutting.
Turret Presses
Turret presses are another method of cutting metal. A turret/punch press is a type of press that cuts metal items by punching holes in them. Using a turret press takes time, depending on the size of the part. However, if you produce the same parts on a regular basis. Then, it is worth using a turret punch press.
Conclusion
When choosing between water jet and laser cutting processes, you should first compare the two. To help you do this, this article has provided a comprehensive overview of both cutting processes. While this may give you an idea of the better process.
However, the best way to determine the best cutting method for your project is to get guidance from a professional. Do you have questions about waterjet or laser cutting? Contact our team of experts.
FAQ
What is the Biggest Advantage of Waterjet Cutting Over Other Cutting Methods?
The main advantage of waterjet cutting over other cutting techniques is that it does not generate heat. It is therefore compatible with all materials and ensures the safety of the operator. Another advantage of the process is its adaptability to cutting thick materials. This is because this method can cut materials from 0.4 inches to 2.0 inches (10 mm to 50 mm) thick.
Which is Better, Waterjet Cutting or Plasma Cutting?
In general, most customers prefer waterjet cutting to plasma cutting. However, the specifics vary depending on the needs of the project. Waterjet cutting is better suited for thicker materials, greater material compatibility, and greater accuracy. In addition, plasma cutting can lead to a decrease in cut quality. This is because plasma may produce unwanted slag.