April

Waterjets vs. Plasma Cutting Machines: A Beginner’s Guide

Category PLASMA CUTTERS, CNC, Waterjet Cutting MachinesTags: Beginner’s Metal Cutting, CNC Plasma Cutting, Fabrication Tools, flow waterjet, How to Use a Plasma Cutter, How to Use a Waterjet, metalworking machines, Plasma vs Waterjet Comparison, sterling machinery, Used Cutting Machines, Waterjet vs Plasma Category Brands: Flow, Flow International

Trying to decide between a waterjet and a plasma cutting machine but don’t know where to start?

Whether you’re a hobbyist, metal artist, or small business owner, choosing the right cutting machine can make or break your workflow. In this beginner’s guide, we’ll break down what each machine does, when to use them, and which is best for different types of projects.

When to Use a Waterjet or Plasma Cutter

Each machine has unique strengths depending on what you’re cutting and how precise the results need to be. Here’s a quick guide to help you decide:

Waterjet: For Multi-Material Precision
Perfect for cutting metal, stone, glass, and even plastic. A waterjet cuts without heat, so there’s no warping. Great for detailed, high-precision parts.
Plasma: For Fast Metal Fabrication
Ideal for cutting steel, stainless steel, and aluminum quickly. Plasma is best when speed is more important than extreme precision.
Waterjet: When You Need Clean Edges
Waterjets offer a smooth finish without secondary processing—no burrs, heat-affected zones, or slag.
Plasma: When Budget is a Concern
Plasma systems are generally more affordable and faster, making them ideal for fabricators who need fast turnarounds.

Know the Parts of a Waterjet and Plasma Cutter

Understanding the main parts of each machine helps you get the most out of them. Here’s a quick overview:

Waterjet Cutter Parts

High-Pressure Pump
Pressurizes water up to 90,000 PSI, creating the force needed to cut through materials.
Abrasive Hopper
Adds garnet or other abrasive material to the water stream for cutting tougher materials like metal or stone.
Cutting Head/Nozzle
Directs the high-pressure stream with precision; includes orifice and mixing tube.
Catcher Tank
Collects spent water and material after the cut.

Plasma Cutter Parts

Power Supply
Generates the electrical arc that forms the plasma used for cutting.
Plasma Torch
The hand or CNC-controlled part that directs the plasma arc to the material.
Ground Clamp
Completes the electrical circuit for cutting and ensures safety and consistency.
Air Compressor
Supplies the compressed air needed to create plasma (some systems use nitrogen or oxygen for better results).

How to Use a Waterjet or Plasma Cutter in 5 Steps

1. Take Proper Safety Precautions

Always wear eye protection, gloves, and proper work attire. Keep the cutting area clear of flammables and ensure all hoses and cables are in good condition. Use hearing protection with plasma systems due to the noise levels.

2. Set Up the Machine and Load the Material

Secure your workpiece to the cutting table. Make sure it’s level and firmly held in place. For waterjets, ensure the tank is filled and abrasives are loaded. For plasma cutters, check air pressure and ground the machine properly.

3. Choose and Input the Design

Use your machine’s software (often CNC-compatible) to load or draw your part design. Set cutting paths and parameters based on material type and thickness.

4. Calibrate and Run a Test Cut

Do a test run on scrap material to verify settings, adjust the nozzle height, and confirm cutting speeds. Waterjets often require more setup time but deliver cleaner results.

5. Cut and Clean the Part

Start the cutting process and monitor progress. Afterward, remove the part, inspect for accuracy, and clean off any residue or burrs. Waterjet cuts may need drying; plasma cuts may need minimal grinding.

🎥 Watch a Flow Waterjet in action here:

👉 Watch the Video on MachineryTube

The History of Flow Waterjet & the Legacy of Precision

Flow International has been a pioneer in waterjet technology since the 1970s. Their high-pressure waterjet systems revolutionized the way manufacturers cut material—without heat, distortion, or compromise. Flow’s innovative solutions are used around the world in aerospace, automotive, metal fabrication, and even art.

Plasma cutting, on the other hand, has evolved rapidly since its introduction in the 1950s, offering faster and more affordable options for metal fabrication. Modern CNC plasma systems are now highly efficient, easy to use, and ideal for small shops and large manufacturers alike.

At Sterling Machinery, we carry top brands like Flow Waterjet as well as trusted plasma systems, offering the best of both worlds for whatever your project needs.

Find Waterjets, Plasma Cutters, and More at Sterling Machinery

Sterling Machinery Exchange has been helping businesses and fabricators find the perfect machine since 1954. Whether you’re looking for new or used waterjets, CNC plasma cutters, or need help deciding what’s right for your shop, our team has the expertise to guide you every step of the way.

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📞 Call us today at 626-444-0311 or visit www.SterlingMachinery.com
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