Multi-process cutting is the use of two or more different types of tools to produce a single part. Often each process is optimized for different results, such as speed or accuracy. But by combining the processes on one CNC machine, you can produce parts that take advantage of the features of each tool.

One of the best examples is the Waterjet / Plasma combination. Both of these cutting tools can cut Carbon Steel, Aluminum, and Stainless Steel. Plasma cuts faster and cheaper, but not as accurate as waterjet. Waterjet is much more accurate, but is more expensive to operate. By combining both processes on one CNC machine, they can both be used on the same part, producing a part that uses a precision process where necessary, but takes advantage of a high-speed process wherever possible.

The result is better parts, at lower cost.

Water Jet / Plasma Combination Cutting

ESAB's patented water jet/plasma combination uses the speed of plasma and the accuracy of water jet to produce parts with precision contours at a fraction of the cost of most water jet machines. The waterjet process can also be combined with many other cutting or marking process tools, including oxyfuel cutting, plasma marking, ink-jet marking, routing, drilling or scribing.

The water jet cutting process typically costs about $30/hour to operate, and cuts metals in the .5 to 10 ipm range. By comparison, the plasma process costs about $15/hour to operate, and cuts in the 30 to 150 ipm range.  

Since many production parts only require high precision on a small percentage of the contours, then why cut the entire part with a slower, more expensive process? Click here to see how the water jet / plasma combination pays for itself on a typical production part.

Water Jet / Oxy Fuel Combination Cutting

By combining the oxy fuel process with the water jet process, parts can be made from thick carbon steel plate that might otherwise be impossible to cut. Oxy fuel cutting is the most economical cutting process for carbon steel. But waterjet can exceed the cut quality of oxy fuel cutting, and is limited in thickness only by its speed.

The advantage of combining waterjet and oxy fuel on the same machine is that both tools can be used on the same parts. Contours requiring high precision can be cut with waterjet, while other contours can be cut with oxy fuel. This system allows users to produce the precision contours they need without sacrificing speed on every cut.

Since many production parts only require high precision on a small percentage of the contours, then why cut the entire part with a slower, more expensive process?

Plasma / Drill Combination

By combining a cutting process with a drill tool, finished parts can be produced in a single machine setup. The drilling process layout is more accurate, since it is done on the same machine as the cutting, and offsets are CNC controlled. Overall processing time is reduced, as well as part handling.

A drill station can be combined with plasma, oxy fuel, or water jet cutting processes on the same machine.

Process combinations are available on many of ESAB’s larger gantry and water jet machines: