Eben in Pongau. The plastics industry is a hard place to be, as it is under increasing pressure to innovate both in ecological and technical terms. Rapid technological developments in the fields of mobility, aviation and medical technology are presenting companies with new challenges at ever shorter intervals. This opens up new opportunities, especially for the processing industry, but at the same time forces it to be extremely flexible. Structures and processes are constantly being reviewed and changed in order to remain competitive in the distant future. At the same time, the focus is increasingly shifting to one manufacturing process: Waterjet technology. The reason: Water is the only tool with which you can cut everything without any other tools. It is constantly renewing itself and is therefore also suitable for production under high hygiene standards. The cold-cutting technique generally enables exceedingly gentle and clean working and cuts even the finest and most complex structures accurately, reproducibly and virtually fully automatically with tolerances of +/- 0.1 millimetres. Thanks to the very thin die clearance of/ 0.1 millimetres, this technology is not only fast but also delivers high material efficiency with minimum tool wear. Post-processing is usually not necessary. Likewise, in contrast to thermal cutting techniques, neither hardening or tension on the workpiece nor health-endangering steam, dust or smoke occur during the cutting process. To summarise, all customary composite materials in thickness extending from a thin film through to thicknesses of 200 mm can be cut environmentally and inexpensively using the waterjet. Above all, prototypes, precision moulded parts and small series can be produced more economically using waterjet technology than with stamping or injection moulding. On top of that, this technology is ideal for just-in-time production and thus minimizes storage costs, among other things. The modular cutting system from Europe's leading manufacturer STM, which can be customised down to the last detail, is the best example of this. It offers users an unprecedented mix of possibilities to solve the most diverse cutting tasks in the best possible way without the need for changeover. Even more, the innovative manufacturer also offers interested companies free management consultancy services including business plans, demand analyses, cost-benefit calculations, digitisation issues and process optimisation for production. For this purpose, an experienced STM application engineer will develop concrete waterjet solutions on request, which will be verified with test cuts and can be mastered through training – all free of charge and without obligation. Thanks to these services, interested parties can get “hands on” experience with this future technology before making an investment. Further information on waterjet production “powered by STM” can be found on the homepages of the STM sites in Austria, Germany and Switzerland.

There's no such thing as impossible

Water can in fact be used to separate a wide variety of plastics and composites up to a thickness of 200 millimetres without additional tools and without any residue. Glorious conditions especially for prototype construction, small and medium series as well as just-in-time production. The cutting process is suitable for rubber, the most common elastomers like EPDM, CR, NBR, silicone, FPM/FKM (Viton®), engineering plastics like PA, PE, POM and above all foam and compound materials. Especially thick porous materials can be cut without deformation. Parallel cuts are guaranteed even for very soft materials. In fact, the most complicated shapes can be transformed directly from drawing to final product with the help of waterjets. As a template, CNC-controlled waterjet cutting systems require only CAD data, e.g. in DXF or DWG format – the rest practically takes care of itself. The parts can even be labelled in one step with waterjet engraving. Waterjet cutting thus not only extends the scope of action and flexibility, but also dramatically reduces manufacturing costs thanks to automation, shorter production times, minimal reworking and the elimination of tools. This is also helped by the material savings due to small cutting widths and the nesting of several parts. Whether standard products or precision moulded parts – there is no manufacturing solution for prototypes, small and medium series with comparable advantages in terms of cutting quality, versatility and efficiency.

Unbeatable even in comparison

It is easy to deduce what the advantages are compared to alternative separation processes: Above all, prototypes and special designs can be produced faster and more economically than with punching. In addition, even the most filigree contours and high material thicknesses are possible without the high tolerances and concave cuts that are common with punching. Not only does this eliminate the costly production, modification, maintenance and storage of the usual punching dies, but also their assembly. In the time it takes to position the punching die, a waterjet system has already completed cutting. The waterjet process is superior to lasers for greater material thicknesses and all applications where thermal influence on the material and thus structural changes are undesirable. This makes cold cutting technology particularly interesting for the booming composites. Even in comparison to oscillating knives on plotters and 3D printers, the performance spectrum and quality are simply more convincing. Material thicknesses of more than 100 mm and composite materials can be cut with more precision, and smaller corner radii and more filigree contours are also possible. Moreover, the tool does not become blunt and the workpiece is spared the machining forces. Water as a cutting tool is even preferable to manual work, as it ensures faster, reproducible results and higher accuracy. In addition, several cutting heads can be used in parallel to significantly reduce production time. Waterjet cutting has proven to be the ideal production technology solution, especially for series of up to 500 pieces.

Waterjet power made to measure

Above all, modular waterjet cutting systems from STM guarantee the required quality, functionality and efficiency, which are absolutely essential in the plastics processing industry. Together with business and technical advice and unparalleled customer-oriented service, STM ensures that the company can discover the potential of this technology for itself and operate trouble-free, economically and with ultimate flexibility. The proven STM portal systems with their lightweight design can be adapted to plastics processing down to the last detail. This is ensured by the fully compatible STM module system, which enables 2D and 3D production with pure water or abrasive and any number of cutting heads with every conceivable form. Needless functions do not have to be accepted, handling is convenient, maintenance requirements are low. The user-friendly SmartCUT software speeds up work preparation and eliminates tedious programming for users. Problems can usually be solved quickly and cost-effectively via remote maintenance. STM also offers complete water treatment solutions especially for industries like the sealing industry, where cutting is carried out with drinking water quality to achieve optimum cutting performance. This allows simultaneous reuse of the cutting water and the dehydrated particles can be conveniently disposed of via Big Bag. Up to 98 percent of fresh water can be saved this way. In the field of composite materials, optional components like drilling spindles guarantee smooth operation.

The acquisition costs for STM systems in the 2D field are between 80,000 and 150,000 € and thus represent a low-cost investment in the truest sense of the word – especially since the operation of waterjet systems is subsidised throughout the EU. Thanks to the fact that STM uses only series components that are available on a long-term basis, the systems also have an almost unlimited service life. They can be upgraded at any time or exchanged for larger systems.

The proof is in the pudding

Whether and how waterjet technology can be used for specific manufacturing processes is assessed by STM specialists within a few days on the basis of non-binding demand analyses, cost-benefit calculations or business plans. But not only that: At STM, interested parties can also have their own workpieces test cut or operate test machines without obligation. Second-hand systems and financing models mean that procuring a machine is still possible even if the room for financial manoeuvres is limited. Parallel to this, workshops are offered to familiarize newcomers with the technology and business management aspects without obligation. STM thus offers interested users an all-round risk-free option to take advantage of the fastest tool technology. In fact, a call to the STM test centres in Austria, Germany or the Switzerland is sufficient.