Waterjet cutting

Waterjet cutting is a precise cut-to-size process for elastomers, in which a high-pressure water jet separates defined contours from the material. The process is particularly suitable for technical rubber parts where clean cut edges, high contour accuracy and reproducible results are required.

In industrial production, waterjet cutting is used above all when complex geometries, internal cut-outs or small to medium batch sizes are to be produced economically. Especially in technical applications where function, fit and material behaviour interact, the process offers a reliable basis for consistent quality.

What is waterjet cutting?

In waterjet cutting, water is forced through a fine nozzle under very high pressure. This creates a focused high-speed jet that separates the material along a predetermined cutting path.

For elastomers, pure water is used in many cases. This preserves the material structure and the machining is carried out without thermal stress. In contrast to thermal processes, no melted areas, no hardening and no change in the elastic properties occur.

The process is particularly suitable for flat materials such as rubber sheets, roll goods or technical cut pieces where contour and dimensional accuracy play a central role.

How it works in detail

The cutting head is guided along the desired contour by CNC control, so that both simple outer shapes and complex internal contours, hole patterns and recesses can be produced precisely. The quality of the result arises from the interaction of several parameters: water pressure determines the cutting performance and enables clean cuts even with greater material thicknesses, the feed rate directly influences edge quality and contour stability, an optimally matched feed rate ensures uniform cut patterns, the nozzle distance controls the focusing of the water jet and thus the precision, and the material properties such as hardness, elasticity and thickness determine the process design. These factors are matched to the material and component, so that a reproducible, dimensionally accurate and technically clean result is achieved.

Advantages when cutting rubber to size

• High dimensional accuracy: Contours can be produced with tolerances of around ±0.1 mm, ideal for technical components and seals
• Gentle machining: No heat input, so elasticity and material structure are fully preserved
• Clean cut edges: Uniform, almost burr-free edges allow direct further processing
• High flexibility: Contours can be produced directly from CAD data, adjustments possible at any time
• Cost-effectiveness for variants: Particularly efficient for small series, prototypes and changing geometries

Suitable materials and their properties

Material	Properties	Typical applications
EPDM	Very good weather, UV and ozone resistance, temperature-stable	Outdoor applications, seals, facades, roof systems
NBR	High resistance to oil, fuels and greases	Mechanical engineering, automotive, technical seals
SBR	Good mechanical properties, economical to use	Standard applications, mats, technical cut pieces
NR (natural rubber)	Very high elasticity and resilience	Dynamically stressed components, vibration elements
CR (neoprene)	Good resistance to weather, chemicals and ageing	Industrial applications, protective and sealing components

The choice is always made depending on the area of application, temperature, media contact and mechanical load.

Typical components produced by waterjet cutting

Flat gaskets

Flat gaskets are among the most common applications in waterjet cutting. They are made from sheet material and are used wherever components must reliably seal against one another. The process also allows complex geometries with internal contours, openings or hole patterns to be produced precisely.

Especially for technical seals, the combination of dimensional accuracy and a clean cut edge is relevant, since even small deviations can affect the sealing effect. Waterjet cutting enables consistent quality here, even with varying contours or smaller series.

Inserts and shims

Inserts and shims often serve as protective, damping or compensating elements in machines, systems or assemblies. They are manufactured exactly to size in order to level surfaces, distribute pressure or protect sensitive components.

Waterjet cutting enables a precisely fitting adaptation to existing constructions. Recesses, contours or functional openings can also be integrated directly, which eliminates additional machining steps.

Vibration dampers

Rubber components for vibration and oscillation damping must be precisely defined so that they reliably fulfil their function. Waterjet cutting offers the possibility of producing geometries precisely and reproducibly.

Typical applications are decoupling elements, bearing plates or damping inserts in machines and systems. The uniform cut quality ensures that the components rest cleanly and fulfil their function across the entire surface.

Mats and cut pieces

Individual mats and large-format cut pieces are frequently used in industrial applications, for example as supports, protective surfaces or functional work areas. Waterjet cutting makes it possible to cut even large formats exactly to size and adapt them to specific requirements.

In addition to simple rectangular cut pieces, complex outer contours, recesses or adaptations to existing systems can also be realised. This results in high flexibility combined with reproducible quality.

Process requirements and technical coordination

For reproducible results, material, thickness, contour and tolerance requirements must be matched exactly. The basis is usually a technical drawing or a digital contour file.

The following factors also play a role:

• desired edge quality
• mechanical stress in use
• installation situation of the component
• quantity and repeat accuracy

Clean technical coordination ensures that the cut-to-size part is produced in a functionally and economically optimal way.

Tolerances and dimensional accuracy

In waterjet cutting, tolerances in the range of ±0.1 mm can be achieved. The actual dimensional accuracy depends on the material, thickness and geometry.

Elastomers behave flexibly and must always be assessed according to their material type. The achievable precision is therefore considered in the context of the application.

For technical components, repeat accuracy is particularly relevant so that assembly and function are reliably guaranteed.

Cut quality and edge appearance

The quality of the cut edge is a central feature of waterjet cutting. Uniform edges facilitate further processing and improve the fit.

With optimally set parameters, clean, almost burr-free cut surfaces are produced. Even with complex contours, the quality remains stable.

Distinction from other processes

• Punching: Very cost-effective for large series and simple geometries, but limited with complex contours and a wide variety of variants
• Knife and plotter cutting: Suitable for thin materials, limited precision and restrictions with greater material thicknesses
• Laser cutting: Thermal influences can change material properties, so only conditionally suitable for elastomers
• Waterjet cutting: High precision, gentle machining and flexible with complex geometries as well as changing requirements

Areas of application

• Automotive industry: Seals, decoupling elements, functional components and interlayers with defined tolerances
• Mechanical engineering: Protective layers, damping elements, inserts and precisely fitting cut pieces for systems and assemblies
• Medical technology: Precise elastomer parts with clear material requirements and reproducible quality
• General industry: Mats, supports, technical rubber components and individual cut pieces for a wide range of applications

Prototypes and series production

Waterjet cutting is suitable both for prototypes and for series. Individual parts can be produced and tested quickly. Adjustments to contours or dimensions can be integrated flexibly.

In series production, CNC control ensures consistent quality and reproducible results.

When does waterjet cutting make sense?

• Complex internal and external contours
• Small to medium quantities
• High requirements for dimensional accuracy
• Sensitive materials
• Frequently changing geometries

Enquiry and technical coordination

For an economical and technically clean production of waterjet-cut rubber parts, precise coordination in advance is required. The decisive parameters are already defined during the enquiry stage in order to optimally match material, process and production to one another.

The most important details include material type, material thickness, desired contour, quantity as well as the requirements for dimensional accuracy and edge quality. Especially for technical components, the function in later use plays a central role, since this influences the choice of material and the design of the cutting process.

The next step is the technical assessment. This determines whether waterjet cutting is suitable for the application, which tolerances can realistically be achieved and how the components can be produced economically. Aspects such as nesting, material utilisation and series logic are also taken into account.

Structured coordination ensures that the cut-to-size part is not only produced geometrically correctly, but also functionally meets the requirements. This results in components that can be directly further processed or assembled and function reliably in use in the long term.

Frequently asked questions about waterjet cutting of rubber

Which rubber materials are suitable for waterjet cutting?

NR, SBR, EPDM, NBR, CR and technical elastomers, among others, are processed. Suitability depends on material density, Shore hardness and sheet thickness.

Which material thicknesses can be cut?

Thin films and solid rubber sheets can be machined equally well. The maximum economical thickness depends on the material type and contour geometry.

Which file formats are required for cutting to size?

DXF and DWG files are customary. Alternatively, technical drawings or sample parts can serve as a basis.

Is waterjet cutting suitable for series?

The process is suitable for prototypes, small series and near-series production. For very large quantities, alternative processes are considered.

How clean are the cut edges?

The cut edges are uniform and burr-free. Additional post-processing is generally not required.

Submit a technical enquiry

For waterjet-cut rubber parts, we coordinate material, contour, tolerances and quantities on a technical basis. On this basis, process-reliable production takes place.

Use the rubber machining entry point for this or send your technical data directly for review.