Sector · Composites
Waterjet Cutting of Composites
Carbon fiber, fiberglass, kevlar and honeycomb sandwich. No burning fibers, no HAZ, no delamination. The choice of Airbus, Boeing and competition.
Polymer matrix composites reinforced with fibers (CFRP, GFRP, aramida) are strategic materials in aeronautics, competition automotive and wind energy. Their most well-known limitation: they are difficult to machine without damaging the fibers or the matrix.
Abrasive waterjet is the standard method to cut composites in the civil aeronautical industry. Airbus and Boeing define in their manufacturing specifications the use of waterjet for cutting structural parts in CFRP (tail planes, flight control surfaces, empennage). No HAZ, no carbonization, no emission of toxic fumes like with laser.
Cutting parameters by composite
| Material | Thickness | Quality Speed | Recommended Garnet |
|---|---|---|---|
| CFRP (carbon) | 2 mm | 800 mm/min | 120 mesh |
| CFRP (carbon) | 10 mm | 450 mm/min | 120 mesh |
| GFRP (glass) | 5 mm | 900 mm/min | 80 mesh |
| Aramid (Kevlar) | 6 mm | 380 mm/min | 120 mesh |
| Honeycomb sandwich CFRP | 20 mm | 600 mm/min | 120 mesh |
| GLARE (Al + fiberglass) | 3 mm | 320 mm/min | 80 mesh |
Typical applications
Civil Aeronautics
Structural parts A350/B787 in CFRP, floor panels with honeycomb Nomex, interior cabin parts, radomes, fairings.
Competition Automotive
F1/MotoGP monocoque chassis, wings, diffusers, aerodynamic parts in carbon. Prototype cutting in very short series without tooling.
Wind Energy
Wind turbine blades in GFRP and hybrid CFRP. Cutting structural parts and inspection windows in thick laminates.
Defense and Armor
Ballistic parts in aramida, lightweight vehicle armor, UAV components and reconnaissance satellites.
Occasional project in composites? Cortalia
Cortalia offers waterjet cutting service for aeronautical and competition composites. Certification tests without commitment before investing in your own machine.
View Cortalia service →Frequently Asked Questions
Why is carbon fiber (CFRP) cut with waterjet and not with laser?+
The laser burns the carbon fibers and degrades the epoxy matrix, creating a heat-affected zone of 0.5-2 mm that weakens the part and releases toxic particles. The waterjet cuts cold without altering the resin or carbonizing fibers. It is the standard method in aeronautics (Airbus A350, Boeing 787) and competition (MotoGP, F1) for structural parts in composites.
What types of composites does waterjet cut well?+
Carbon fiber (CFRP), fiberglass (GFRP), kevlar/aramida, hybrid composites, honeycomb core sandwich (honeycomb Nomex or aluminum), laminates with foam, and composites with metal (GLARE). The waterjet cuts all without delaminating or burning, unlike mechanical methods which tend to fray edges.
Does waterjet delaminate composites?+
With correct parameters, no. The key is to use the appropriate cutting speed (fast feed and low pierce), fine abrasive (garnet 120 mesh better than 80), and keep the head at minimum distance (3-4 mm). With OMAX the Intelli-MAX software has material-optimized parameters included from the factory. Typical delamination <0.1 mm.
What speeds are reached cutting composites?+
Carbon 2 mm: 2,500 mm/min separation speed, 800 mm/min quality speed. Carbon 10 mm: 450 mm/min quality speed. Honeycomb with carbon faces 20 mm total: 600 mm/min. Fiberglass is faster as it is easier to erode. Parameters with OMAX 55100 + garnet 120 mesh.
Which OMAX model is best for aeronautical composites?+
For wing or fuselage part production: OMAX 55100 (3.2×1.65 m) or 5555 (1.7×1.7 m) depending on part size. For F1/MotoGP prototypes: OMAX 2626 or 2652 are ideal. OptiMAX with Tilt-A-Jet allows automatic taper compensation — useful when tolerance requires <0.1 mm on vertical edge.
Consult your composite project
Material type, thickness, annual volume and tolerances. We indicate the optimal OMAX model and estimated ROI.