Composite materials

Waterjet cutting is an effective method for cutting a range of composite materials, such as carbon fibre-reinforced plastics, fibreglass and Kevlar. The high-speed jet of water used in abrasive waterjet cutting can cut through almost any material, making the technique particularly useful for complex and detailed shapes. It has a low contact force which eliminates the need for bulky tools and minimises the risk of delamination or damage to the material.

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Carbon fiber or glass fiber reinforced materials CRP, CFRP, GRP, GFRP and C/C

One of the main advantages of waterjet cutting is that it is a cold method. This means that the material is not exposed to heat, which can change its properties or cause melting and deformation. This is particularly important when processing composites, where heat can lead to undesirable changes in the structure of the material. ​

Waterjet cutting is also versatile and can be used for composites made up of different materials, such as metal and rubber, in one single process. The fine, concentrated water jet cuts reliably and precisely in all directions with meticulous accuracy. This is what makes the technique ideal for applications where precision and quality are crucial.

Keywords explained

Waterjet cutting composites

Waterjet cutting composites means cutting reinforced, layered or hybrid materials with a focused ultra high-pressure waterjet. It is often used when the material requires precision, low heat impact and reduced risk of edge damage.

Composite materials

Composite materials are made by combining two or more materials to achieve specific properties, such as low weight, high strength, stiffness or resistance to wear. Common examples include carbon fiber composites, fiberglass composites and aramid fiber composites.

CFRP

CFRP stands for carbon fiber reinforced plastic. It is a lightweight and strong composite material often used in aerospace, automotive, motorsport and advanced industrial applications.

GFRP

GFRP stands for glass fiber reinforced plastic. It is a composite material made with glass fibers and polymer resin, often used in industrial parts, panels, marine applications and structural components.

Kevlar composites

Kevlar composites are reinforced with aramid fibers. They are used in applications where strength, low weight and impact resistance are important.

Delamination

Delamination means that layers in a composite material separate from each other. In composite cutting, reducing the risk of delamination is important for maintaining strength, edge quality and part performance.

Fibre pull-out

Fibre pull-out occurs when fibres are pulled from the composite edge during cutting. A controlled cutting process can help reduce fibre damage and support cleaner edges.

Hybrid composites

Hybrid composites combine different materials or fibre types in one structure. Examples can include combinations of carbon fiber, glass fiber, rubber, metal or other reinforcement materials.

Laminate structure

Laminate structure describes how the layers in a composite material are built up. Fibre direction, layer thickness and resin type can all affect how the material behaves during cutting.

Composite trimming

Composite trimming means cutting or finishing the edges of a molded or formed composite part. Waterjet cutting can be useful for trimming complex composite parts with repeatable accuracy.

Specify your composite cutting needs

To recommend the right waterjet solution for composite cutting, it is important to understand both the material structure and the production requirements. Composite materials can vary in fibre type, laminate structure, thickness, resin system, surface finish and sensitivity to delamination, which means the cutting setup should be adapted to the specific application.

When contacting Water Jet Sweden, please share information about the composite material type, sheet or part size, thickness, fibre reinforcement, laminate structure, tolerance requirements and expected production volume. If the material is CFRP, GFRP, Kevlar, fiberglass, a sandwich panel or a hybrid composite, this information is important for evaluating the right process.

Drawings or CAD files can help define cutting paths, holes, internal cut-outs, curves and the required level of detail. It is also useful to describe whether the component is flat, molded, curved or three-dimensional, since complex geometries may require a more advanced machine setup or 5-axis cutting.

Please also include information about edge quality requirements, visible surfaces, post-processing needs and current production challenges. This could include reducing delamination, improving repeatability, cutting complex shapes, reducing dust or moving from manual trimming to a more controlled digital cutting process.

With the right information, Water Jet Sweden can help evaluate the most suitable machine configuration, cutting head setup, software workflow, abrasive process and production solution for your composite cutting needs.

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FAQ

Can waterjet cutting be used for composite materials?

Yes, waterjet cutting can be used for many composite materials, including carbon fiber, CFRP, GFRP, fiberglass, Kevlar, aramid fiber composites, laminated composites and hybrid composite materials.

The best cutting setup depends on the material structure, thickness, fibre type, edge quality requirements and production volume.

Why is waterjet cutting suitable for composites?

Waterjet cutting is suitable for composites because it combines high precision and low mechanical force with a cold cutting process, drastically reducing the risk of material damage. Since no heat is generated during operation, the material is protected from melting, deformation, or structural changes to heat-sensitive resins. The fine, concentrated water jet exerts minimal pressure and vibration, making it gentle on reinforced and layered materials while reliably executing detailed shapes, internal cut-outs, and complex geometries in all directions. Additionally, its versatility allows it to cut through multi-material composites—such as combinations of metal and rubber—in a single process where meticulous accuracy and quality are crucial.

Can waterjet cutting reduce delamination?

Yes, waterjet cutting can help reduce the risk of delamination when the process is correctly configured. Since the cut is made with a focused waterjet rather than a mechanical blade, the material is exposed to less mechanical force.

Delamination is often a critical parameter to test when working with new composites—each having its own unique properties—and combined/multi-layer materials.

Cutting speed, pressure, abrasive flow, nozzle setup, and material support all affect the final result. For composite and multi-layer materials, piercing is the most critical part of the waterjet cutting process.

To prevent delamination in sensitive materials during hole punching, the waterjet machine can be equipped with a physical drilling unit to create the initial starting holes. Once the waterjet has cut completely through the material and cleared the initial hole, the risk of delamination is significantly reduced.

When in doubt, we always recommend contacting us for a test cut so we can define the right parameters, find the optimal processing method, and ensure that waterjet cutting is the best solution for your material.

Can waterjet cutting be used for carbon fiber and CFRP?

Yes, waterjet cutting can be used for carbon fiber and CFRP materials. These materials are often used where low weight, strength and precision are important.

Abrasive waterjet cutting can process CFRP without heat-affected zones, making it useful for aerospace, automotive, motorsport and advanced industrial components.

Can waterjet cutting be used for fiberglass and GFRP?

Yes, waterjet cutting can be used for fiberglass and GFRP materials. The process can cut reinforced glass fiber materials into panels, technical parts, structural components and custom shapes.

Because waterjet cutting is a non-thermal process, it can help avoid heat-related damage and support consistent edge quality in reinforced materials.

Why is cold cutting important for composite materials?

Cold cutting is important for composites because heat can affect the resin, fibres or bonding between layers. Thermal cutting methods may cause melting, burning, deformation or changes in the material structure.

Waterjet cutting avoids heat-affected zones, helping the material retain its original properties after cutting.

Can waterjet cutting create complex shapes in composite parts?

Yes, waterjet cutting can create complex contours, holes, internal cut-outs, curves and detailed shapes in composite parts. This makes it useful for both flat sheets and more advanced components.

For molded, curved or three-dimensional parts, 5-axis waterjet cutting may be useful to follow the geometry of the component.

Is waterjet cutting suitable for composite trimming?

Yes, waterjet cutting can be suitable for trimming molded or formed composite parts. It can help create repeatable cutting paths, reduce manual trimming and improve consistency between parts.

This is especially useful when producing high-value components where edge quality, accuracy and repeatability are important.

What affects edge quality when cutting composites?

Edge quality is affected by the composite material, fibre type, laminate structure, thickness, cutting speed, pressure, abrasive flow, nozzle setup and material support.

For high-performance composite parts, edge quality requirements should be defined before production. Test cutting can help identify the best process settings.

What information should I provide for a composite cutting application?

To evaluate a composite cutting application, it is helpful to provide the material type, thickness, fibre reinforcement, laminate structure, part size, geometry, tolerance requirements and expected production volume.

It is also useful to share CAD files or drawings, information about visible edges, post-processing needs, delamination concerns and whether the part is flat, molded, curved or three-dimensional.