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Opportunity isn’t what it once was for U.S. moldmakers. Global competition is creating new challenges in customer retention, labor and raw material costs. Domestically, moldmakers are looking to combat a shrinking mold market by diversifying, and opening doors to new markets such as energy, aerospace, defense and medical.

Waterjet cutting is one of today’s most versatile and fastest-growing technologies. It uses a high-pressure stream of water with an abrasive—such as garnet—to cut. Waterjet can cut virtually any material including glass, ceramic, wood, stone, plastic and rubber. This versatility is highly appealing to shops that are seeking diversification because it allows them to fill the supply chain of companies in many new industries.

The Versatility
One customer, Mac Mold Base, Inc. (Romeo, MI), a custom mold base manufacturer of nearly 20 years, was looking to expand its capabilities.

“We had been considering waterjet technology as a way to improve our process and branch into new markets for many years,” says Dave Gifford, waterjet operations of Mac Mold Base. “We saw the improvements the technology had made in recent years and decided the time was right to purchase one.”

With waterjet technology the possibilities are endless for domestic moldmakers that are choosing to expand their capabilities. Image courtesy of Mitsubishi Waterjet.

The company integrated a Mitsubishi Waterjet DX612 into its operations. The machine table is 6 feet by 12 feet, and features a 20-inch I-beam construction, 40-millimeter ball screws, and a stainless steel work tank isolated from the machine frame. The unit is controlled with the Mitsubishi 700 series CNC control, featuring advanced programming capabilities, a 15-inch waterproof LCD screen and NC design.

The addition of waterjet resulted in approximately a 30 percent productivity improvement on the company’s general plate machining business. Mac Mold Base is saving time and money in mold plate manufacturing by purchasing sheet stock at a reduced rate and cutting mold base plates to finish size on the precision waterjet.

“The waterjet has changed the way we look at our manufacturing process,” explains Gifford. “We are now able to cut a finished part in one process and rough out material much faster than traditional methods. It often eliminates the need for multiple machining setups and six-way machining.”

Additionally, waterjet’s ability to run unattended on long cuts has eliminated high operator costs at Mac Mold Base as well.

“I can program the DX612 and let it run with minimal supervision most of the day,” Gifford says. “This gives me more time to actively pursue projects in new markets such as aerospace and defense.”

“Mitsubishi provides excellent training and technical support,” recalls Gifford at Mac Mold Base. “I was able to run my first job within two days of installation and can always expect a call back when I have any difficulties.”

In addition to new market expansion, Mac Mold Base has experienced growth with its existing customers as well. These days, the company is being sourced to cut a variety of materials, from mild and tool steels, to aluminum, titanium, foam, rubber, and even Plexiglas.

“I think manufacturers are retraining themselves to look beyond traditional machining processes and take advantage of the waterjet process,” explains Gifford.

Mac Mold Base, a custom mold base manufacturer, incorporated Mitsubishi Waterjet technology to expand its capabilities. Image courtesy of Mac Mold Base.

The Technology
With many years of machine tool manufacturing under its belt, Mitsubishi has developed its waterjet line to achieve higher accuracies and programming capabilities than its competition.

Mitsubishi Waterjet’s gantry-style construction delivers a highly rugged design. The movement system travels the extra rigid box constructed x-axis bridge on a set of linear movement guides driven by dual Mitsubishi Brushless AC Servo Motors and high-pitch 40-millimeter double anchored ball screws for unmatched positioning accuracy.

The DX Series features an extreme-pressure, 60-horsepower KMT pump for fast and efficient cutting. Mitsubishi’s abrasive removal system uses a 300-gallon-per-minute water circulating system in the work tank that suspends the exhausted abrasive and pumps it through a cyclone system that separates the water and returns it to the tank. The used abrasive is collected in a hopper for easy disposal and minimal maintenance overall.

Mitsubishi Waterjet’s redesigned ITC (Intelligent Taper Control) system analyzes the cut and provides taper control without the need for reducing speed. The technology allows for tilt and rotation of the jet to maintain maximum speed with accurate wall straightness. It uses a 1-2 degree mechanical tilt to compensate for the jet getting wider as it exits the focus tube, maintaining stream velocity and faster production of final parts.

The Future
There are many educational and support resources available to companies considering the addition of waterjet technology. The industry’s interest in diversification has resulted in extensive technical and application training classes such as Mitsubishi’s recent partnership with Oakland Community College (Auburn Hills, MI campus).

The possibilities are endless for domestic moldmakers that are choosing to expand their capabilities. Right now is a pivotal time in the manufacturing world, and success is in the hands of the companies that recognize this opportunity. By making themselves more versatile, they are opening the door to new markets and new business.