Manual cutting uses an operator with a knife, drill, pair of scissors, or other handheld tool to cut materials into parts. By contrast, water jet cutting is a machine-based process that cuts materials using a highly-pressurized stream of water that may or may not contain an abrasive. Some water jet cutters are gantry-style tables. Others use industrial robots or multi-axis equipment instead.
Like manual cutting, water jet cutting can be used to produce parts like rubber seals, gaskets, and thermal-acoustic insulation. Most knives and scissors can’t cut metal, glass, or ceramic, however. Pure water jet cutting won’t convert harder materials either, but the garnet particles that are used with abrasive water jet cutting provide the additional cutting power that’s required.
Cab Insulation Case Study
As this time-elapsed video shows, heavy equipment manufacturers can increase their production efficiency tenfold by cutting cabin insulation with water jet equipment instead of by hand. Water jet cutting also reduces material waste and can create features, such as holes and chamfers, that can be difficult to cut by hand. There are additional benefits, such as less waste, as well.
Why Replace Manual Cutting with Water Jet Cutting?
There are seven reasons to replace manual cutting with water jet cutting.
- Precision
- Speed
- Deformation
- Complexity
- Cost
- Waste
- Safety
The following sections explain.
#1 Precision
Manual cutting largely depends on the skill of the operator. For complex shapes or detailed cuts, even experienced personnel may struggle to achieve the accuracy and consistency that’s required for parts like seals, gaskets, and insulation. By contrast, water jet cutting is very precise and can produce intricate parts with clean edges. Because the process is computer-controlled, it’s also consistent.
#2 Speed
Manual cutting is slower than water jet cutting, especially for complex shapes or higher volumes. Plus, manual cutting is time-consuming and can be labor-intensive. Water jet cutting is faster, especially for complex shapes or large production runs. Yet this tool-less process can also produce prototypes and low volumes with speed and efficiency.
#3 Deformation
Depending on the tool that’s used, manual cutting may deform or damage softer materials such as rubber. The pressure that’s applied during cutting can also cause stretching or tearing. By contrast, water jet cutting maintains the integrity of the rubber – and without the risk of burning, melting, or otherwise altering the material.
#4 Complexity
The complexity of the parts that manual cutting can create is a function of a worker’s skills and the available tools. Intricate designs can be difficult to achieve. By contrast, water jet cutting can produce very complex and detailed shapes, including sharp angles and tight curves. With door gaskets and cabin installation, water jet cutting can also create precise holes for fasteners.
#5 Cost
Manual cutting has lower up-front costs because it doesn’t require expensive machinery. However, its labor costs can add up, especially for larger or more complex jobs. Water jet cutting has higher initial setup and equipment costs, but not if you outsource rubber fabrication to Elasto Proxy. You’ll get better quality parts, and you won’t have to use your more expensive employees to make them.
#6 Waste
Manufacturing waste takes many forms, but material waste is especially noticeable when scrap is visible. However, some workers may discard mis-cuts that managers never see. By its very nature, manual cutting is more likely to produce waste due to human error. Water jet cutting is computer-controlled, and it supports nesting for more parts per sheet of material.
#7 Safety
Manual cutting carriers a greater injury of risk because it requires the use of sharp tools that are held in the hand. Water jet cutting isn’t without risk, but this machine-based process requires little direct human action during cutting operations. By outsourcing your water jet cutting to Elasto Proxy, you can further increase shop safety while saving both time and money.
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