Mid-Volume Waterjet Production: Manufacturing of Custom Plastic Components

The Project:

A manufacturing and CNC machining company based in the Northeastern United States specializing in the design and manufacturing of their own products approached Derecktor Design to find a cost effective way to manufacture a number of two dimensional parts.  The parts were needed for the assembly of one of the products that they design and manufacture to sell directly to their end customer.

Though they could make the 2-d parts in-house using their 3-axis CNC machines, due to some of the more detailed features of the part (including small radii and tight corners) plus the volume of parts they needed, it was much more cost effective to have the parts waterjet cut on Derecktor Design’s waterjet machine which is optimized for the efficient manufacturing of 2-d parts.  This proved ideal for the dozen-plus variations of the product required in quantities of 500 each.

Waterjet cutting also is a better alternative over fabrication methods such as laser or flame cutting on this material due to the potential impact of heat zones.

Waterjet Cutting of Plastic Components

How We Approached the Task of Building the Driveline Component

  • Design: The parts are made from UHMW polyethylene, a type of plastic.  Finished pieces are two inches by two inches and .5 inches thick.
  • Fabrication: The 24in x 48in polyethylene sheet is mounted to our Omax 2652 waterjet table. The cutter is programmed with the shapes which are arranged in a pattern to allow minimal waste from the polyehylene sheet. The cutter then leverages a jet of 47,000 psi water mixed with garnet abrasive particles to cut the shapes within the sheet to a precision of +/- .010 inches.

Waterjet Cutter in Action Cutting Pieces from Polyethylene Sheet

waterjet cutting machine cutting plastic pieces with brown bubbles between holes

Waterjet Cutter Shown with Splash Guard on Cutting Head

Waterjet Cutting of Plastic parts

Stacked Parts Ready to Ship

The polyethylene parts were manufactured in runs of about 500 per variation for this job.

Stacked Plastic Parts from Production Waterjet Cutting Job

How Can Derecktor Design Help on Your Next Project?

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