When you’re building something new, flexibility is power. And for startups, waterjet cutting offers a rare kind of adaptability—one that doesn’t force you to compromise between precision, material versatility, and budget. Unlike many other cutting methods, waterjet cutting doesn’t burn, melt, or warp your material. Instead, it slices cleanly with a high-pressure stream of water, sometimes enhanced with fine abrasive particles.
The rising demand for cleaner, more accurate, and material-agnostic fabrication tools has made waterjet cutting a favorite among early-stage manufacturers, prototyping labs, and custom part makers. It’s not just precise—it’s startup-friendly.
After all, when you’re designing a product from scratch, you don’t want limits. And that’s exactly what waterjet cutting helps remove.
Waterjet cutting is a fabrication process that uses a high-pressure stream of water—often mixed with abrasive material—to cut through various substances without generating heat. It’s classified as a “cold cutting” method and is known for its ability to cut virtually any material with remarkable precision.
Can a waterjet really cut through anything?
Not quite everything, but close. Waterjet cutting machines are among the most material-flexible cutting tools available today. Their cold-cutting nature means they don’t change the chemical or physical properties of the material being cut, which is crucial in industries like aerospace, automotive, and medical device prototyping.
You can use waterjets to slice through both soft and hard materials, from foam to stainless steel. The process doesn’t rely on conductivity or melting points, making it uniquely suitable for composites, rubber, and temperature-sensitive materials.
Here’s a snapshot of the materials a waterjet can handle:
- Metals: Steel, stainless steel, aluminum, titanium, copper, brass, Inconel
- Composites: Carbon fiber, fiberglass, Kevlar
- Plastics: Acrylic, PVC, polycarbonate, polyethylene
- Rubber: Neoprene, silicone rubber, EPDM
- Glass: Standard glass, laminated glass (but not tempered)
- Stone: Granite, marble, slate, tile, porcelain
- Other: Wood, foam board, insulation panels, even some food products
How does waterjet cutting work?
At the heart of every waterjet system is controlled force—engineered to erode material without friction. Whether using pure water or water mixed with abrasive particles, the physics behind it is consistent: pressure turns water into a cutting tool.
Here’s how it works, step-by-step:
- Pressurizing the water: A pump drives water to pressures up to 90,000 psi.
- Introducing abrasive (if needed): Garnet or similar media is mixed with the water for harder materials.
- Focusing the jet through a nozzle: The stream is narrowed to a fine, concentrated cutting jet.
- Material erosion and part formation: The jet erodes material in its path, shaping parts as specified by CAD files.
This erosion-based technique is what allows for clean edges and intricate cuts—even in brittle or composite materials.
What types of waterjet cutting systems are available?
There are two main types of waterjet cutting systems, each optimized for different material types and project needs. Choosing the right system comes down to what you’re cutting—and how often.
Pure Waterjet Cutting
Pure waterjet systems don’t use abrasives. They rely solely on the pressure of water to cut soft materials. That makes them ideal for applications where abrasives might contaminate the material or where edge softness is a priority.
Pros:
- Perfect for soft materials (foam, rubber, textiles)
- Lower operating cost
- Minimal wear on cutting components
Cons:
- Limited to soft materials
- Not suitable for metals or composites
Abrasive Waterjet Cutting
Abrasive waterjet systems introduce a granular substance—typically garnet—into the water stream. This boosts cutting power and allows for precise cuts in hard materials like metal, glass, and stone.
Pros:
- Cuts through hard and thick materials
- High precision and edge quality
- Versatile across many industries
Cons:
- Higher operating and maintenance costs
- Requires abrasive handling and cleanup
What materials can be cut using waterjet cutting?
Let’s break down the main categories of materials, along with key attributes that make them suitable—or challenging—for waterjet processing.
Metals
- Steel, aluminum, titanium, copper, brass, Inconel
- Maintain structural integrity (no thermal distortion)
- Ideal for prototyping and short-run production
Composites
- Carbon fiber, fiberglass, Kevlar
- Cold cutting avoids delamination or fraying
- Great for aerospace, defense, and motorsport parts
Plastics and Rubber
- Acrylic, PVC, polyurethane, polycarbonate
- No melting or chemical change
- Useful in packaging, consumer products, and prototyping
Glass and Ceramics
- Standard glass, laminated glass, porcelain, ceramic tile
- Tempered glass cannot be cut—it shatters
- Precision needed to prevent cracking at cut edges
Stone and Tiles
- Granite, marble, slate, porcelain
- Can handle up to 6 inches thick
- Watch for micro-fractures in brittle stone
Wood and Paper Products
- MDF, plywood, cardboard
- Thin cuts possible, but moisture absorption must be managed
What are the cutting tolerances for waterjet machines?
A water jet cutter offers competitive tolerances even at high thicknesses. Though not always as precise as EDM or high-end milling, the results are more than adequate for most industrial and commercial applications.
Typical tolerances:
- ±0.1 mm to ±0.5 mm, depending on system quality and operator skill
- Kerf width: Around 0.8 mm to 1.2 mm, depending on nozzle diameter and material properties
What are the advantages of waterjet cutting for startups?
Waterjet cutting offers unique benefits that align well with startup needs—especially those dealing with diverse materials, limited budgets, and evolving product designs.
Here’s why it works so well:
- Cold cutting = no heat-affected zones
- Can cut nearly any material
- High dimensional accuracy
- No tool wear or thermal distortion
- Low material waste
- No need for secondary finishing in most cases
- Low setup and fixturing costs
- Environmentally cleaner process than plasma or laser
What are the design rules for waterjet cutting?
Great results start with smart design. These tips can help your CAD files translate into clean cuts:
- Avoid sharp 90° internal corners (round them slightly)
- Account for kerf width when sizing parts
- Leave tabs or use fixturing to hold small parts
- Add bridges for letters with internal voids (e.g., “a”, “e”)
- Respect minimum feature sizes (~1 mm or more)
What safety precautions should startups take when using a waterjet cutter?
Safety is critical when working with ultra-high pressure systems. Always:
- Wear PPE (eye protection, gloves, hearing protection)
- Keep enclosure closed during operation
- Use certified, tested high-pressure components
- Monitor abrasive storage and waste
- Perform regular checks for wear, leaks, and fatigue
What makes a good waterjet cutter for startups?
Look for features that support growth, not just your current project:
- Affordable and predictable maintenance
- Reliable, energy-efficient pump system
- Compact size for small shops
- Ability to cut many types of material
- User-friendly software and control system
- Responsive support and training
- Modular options for future expansion
What industries use waterjet cutting and for what?
Waterjet cutting shows up across industries for good reason:
- Aerospace – composite panels, lightweight metals
- Automotive – brackets, gaskets, body components
- Architecture – decorative panels, custom tiles
- Manufacturing – fixture plates, precision tooling
- Food – sanitary, blade-free cutting
- Art & design – custom signs, sculptural forms
- Marine – corrosion-resistant materials and gaskets
How does waterjet cutting compare to other cutting technologies?
Here’s how it stacks up:
Laser Cutting
Pros: Fast, clean edge on thin metals
Cons: Heat-affected zones, limited to certain materials
Plasma Cutting
Pros: Fast for thick steel
Cons: Rougher cuts, lower precision
EDM (Wire Cutting)
Pros: Ultra-precise
Cons: Only works on conductive materials.
If you’re unfamiliar with the process, you can explore what is Wire EDM to understand how it achieves such high precision through electrical discharge
CNC Milling
Pros: Great for 3D shapes and features
Cons: Slower for flat part profiles
Is waterjet cutting environmentally friendly?
Yes—and that’s part of its appeal for modern startups.
- No fumes or toxic emissions
- Water can be recycled in closed-loop systems
- Garnet abrasive is non-toxic and often recyclable
- Reduces material waste compared to subtractive methods
Conclusion
Waterjet cutting isn’t just for large manufacturers—it’s a flexible, startup-ready tool for prototyping, scaling, and staying adaptable. It handles nearly any material, doesn’t need complex setup, and delivers accuracy without heat damage or waste.
If your team is building the future and wants to cut without limits, waterjet technology might just be your smartest first tool.