In an era of increasing industrial demands manufacturing companies are looking for solutions that provide not only high edge quality, but also speed of execution and repeatability of the process. The answer to these needs are modern hybrid systems that integrate different cutting technologies into a single, intelligent solution. Particularly effective is the combination of plasma and waterjet technologies, which enables both instantaneous cutting of 2D contours and precise processing of 3D parts with high quality requirements.

Waterjet cutting - precision without thermal impact

Waterjet technology relies on directing a very thin stream of water at high pressure (up to 6000 bar), which affects the surface of the material being cut with high energy. For difficult-to-cut materials such as steel, an abrasive (e.g. garnet) is added to the stream to increase the effectiveness of erosion. Brittle materials - such as glass and ceramics - are cut with water only, without the addition of an abrasive, thus avoiding microcracks and damage.

Application and advantages of waterjet technology

The high-pressure water jet allows cutting any type of material: metals, ceramics, glass, stone, composites, plastics or wood. Such a wide range of applications gives the user great flexibility in the implementation of diverse projects - from precision details to large structural components.

The key advantages of this technology include:

• The ability to cut a wide range of materials - without limitations due to conductivity or brittleness,
• High accuracy - even with complex geometries and thin layers
• No thermal effects - cut parts maintain exact dimension and shape

The process of 3D cutting stainless steel with Pro-X 3D head using abrasive waterjet technology

Plasma cutting - fast and efficient processing of conductive metals

In plasma technology the material is processed using an electric arc that melts its surface, while compressed gas blows the molten metal out of the cutting gap. The process is carried out with high speed and high precision, making it ideal for separating carbon steel, stainless steel or aluminum.

Application and advantages of plasma technology

Plasma excels at machining all conductive metals - from thin sheets to parts with thicknesses exceeding 100 mm. The range of possible applications depends on the power of the source and the specifics of the technology used, which allows you to match the process parameters to a specific project.

The most important advantages of this technology include:

• Very fast cutting speed,
• High edge quality with conductive materials
• Shorter machining time and savings in batch production

Plasma cutting process on Opal WaterJet Combo machine, implemented with HD3000 head

Merging technologies: what does a plasma-waterjet cutting hybrid offer?

The combination of waterjet cutting with the speed of plasma technology opens up new possibilities for flexible machining of parts with different geometries. Waterjet guarantees the highest accuracy, the possibility of 3D cutting and beveling, which works especially well for complex parts requiring perfect edge quality. Plasma enables instant contour separation, ensuring high productivity and quality when machining conductive metals. Integration of both methods in a single machine allows the technology to be dynamically adapted to the specific area of the workpiece, optimizing the entire process in terms of time, quality and cost.

Most important benefits of the hybrid approach:

• Plasma speed and water jet precision in a single operation
• Work in an integrated environment - no repositioning required
• Possibility to perform flat and spatial cutting (2D and 3D)
• Significant reduction in production time while maintaining high quality
• Intelligent process management - less material and energy consumption

Practical example: the Opal WaterJet Combo machine in action

The following video shows a complete cutting cycle of a stainless steel sample using the Opal WaterJet Combo machine. The video demonstrates the integrated use of plasma and waterjet technology within a single CNC program, without the need for tool changes or repositioning.

Cutting stainless steel using plasma and water technology - a process carried out in a single CNC program

Machine characteristics

The Opal WaterJet Combo model integrates plasma and waterjet technologies into a single, fully automated system. This solution provides continuous operation and the ability to perform a wide range of operations on different materials and thicknesses.

Many of the key features are worth mentioning:

• Automatic switching between technologies without interrupting the program
• Clean water or abrasive water handling
• Pro-X 3D FL head for ±60° angle cutting, with taper compensation
• Supported HD3 3D FL head with taper compensation.
• Support HD3000 with advanced sensors and features Contour Cut®, True Hole®, Diameter Pro®
• Eckert I-Vision controller with ERP/MES integration

Test process specification

The following specification shows the actual parameters of the hybrid (plasma-water) cutting process using the Opal WaterJet Combo CNC machine.

Cutting parameters

Map of technologies used in hybrid cutting process
Blue: water & Purple: plasma

Application of hybrid technology

The technology that combines water and plasma cutting is used in many industries, including:

• Metal and machinery industry - cutting of steel details and mechanical components
• Building and steel structures - load-bearing elements, plates, frames, brackets
• Automotive and aviation - aluminum, titanium, stainless steel parts
• Energy and chemical industry - tank components, piping, covers
• Single and series production -precision components, prototypes, decorative elements

Learn more and contact us

For more information about the combination of waterjet and plasma cutting technologies and their applications, visit our product page - see Opal WaterJet Combo. We also encourage you to visit our knowledge compendium - a rich database of technical articles to inspire you.

Have questions? Contact us - we will be happy to answer, advise and help you choose the best solution for your needs.