Waterjet Cutting Case Studies

Emergency Production Run

Possessing a broken rotary stamp, originally used to make their products, a client from Heater Probes Industrial Dielectric contacted our company requesting that we apply our advanced water jet cutting technology to immediately manufacture a series of heater probe shields. These shields are used as an insulator between two electrical components. Based off a customer-supplied design, we employed white formex, a flame retardant polypropylene, measuring four feet in length and four inches in width, as the base material. Upholding a ± .005” inch precision tolerance, we were able to produce these shields that measured .031 inches in thickness.

Placing parchment paper between each layer to keep the edges from bonding together during manufacturing, we then tumbled each stack to produce a finished product. This process allowed us to both separate the parchment paper from each layer, and to ensure each part possessed a smooth material finish.

Running our machinery for six weeks (with Saturday and Sunday as cushion time), we were able to employ a combination of our water jet machinery and tumbling service to mass manufacture over 25,000 high-quality heater probe shields per day that met NSF specifications (with a minimal cost added for fixtures used for raw material support while cutting). Offering just-in-time service for local, on-site pick-up, Abrasive Waterjet continues to ensure the absolute satisfaction of our clients.

Project Highlights

Product Description
This Insulator is used between two electrical components within a heater application

Capabilities Applied/Processes
Waterjet Cutting (Water Only)
Tumbling
Finishing

Overall Part Dimensions
Length: 4” (Raw Material)
Width: 4” (Raw Material)
Thickness: .031”
Diameter: ø.511”

Tightest Tolerances
±.005”

Material Used
Formex

Typical Machining Operations
Waterjet Machining:
Cut out Insulator to its finished Dimensions

Finishing:
Tumbled to Remove
Burrs
Stacked
Parchment Paper Used to Separate Each Layer

Industry for Use
Appliance

Production Volume
25,600/Day

Production Time
6 Weeks

Delivery Time
Just In Time (J.I.T.)

Delivery
Local Pickup

Standards Met
Manufactured to Customer Standards
NSF Certification

Product Name
Heater Probe Shield

Waterjet Blanking of Riser Handle for an Archery Bow Application

A client recently contacted Abrasive Waterjet, wishing to employ our advanced water jet cutting technology to manufacture a series of riser handles used on an archery bow. Upholding a precision tolerance of ± .010” inches, we were able to blank out each component from 6061 T-6 aluminum. Up to five cavities were meticulously cut into each component, including indexing holes. The finished production process was completed through more traditional milling procedures.

Each component was constructed to measure nineteen inches in length, 3.5 inches in width, and 1.5 inches in both height and thickness. The rough pieces weighed 3 pounds, but after full machining with a CNC mill was completed, each part weighed just two pounds. After production, each component was then packaged in water jet cut foam that was custom fit to each product, ensuring safe delivery.

By employing our advanced water jet cutting technology, as opposed to just using traditional milling procedures alone, we were able to ensure maximum utilization of the aluminum material and offer substantial savings for our client of both production cost and time. With the ability to provide timely, cost-effective, top notch service that met all of our customer’s unique specifications.

Project Highlights

Product Description
This Riser Handle is used within an Archery Bow

Capabilities Applied/Processes
Abrasive Waterjet Cutting

Overall Part Dimensions
Thickness: 1.50”
Length: 19”
Width: 3.50”
Height: 1.50”

Product Weight
3lbs Rough
2lbs Finished

Tightest Tolerances
±.010

Material Used
6061 T-6 Aluminum

Typical Machining Operations

Waterjet Cutting:
Abrasive Waterjet Cutting of Blanks to be finished by Milling Process

Features
5 Cavities Cut into Components
By Cutting Blanks on Waterjet vs. Milling There is a Substantial Savings in Cost and Time
Maximum Utilization of Material

Packaging
Waterjet Cut Foam for a Custom Fit to Product

Secondary Operations
Indexing Holes for Milling Operation

Industry for Use
Archery

Production Volume
1,000 Pieces Annually

Delivery Time
170 Pieces Every 2 Months

Standards Met
Customer Specified

Product Name
Archery Bow Riser