How A Metal Fabrication Company Improved Competitiveness by Replacing Plasma Cutting with HEAD1020BB Waterjet Technology

In the fast-paced world of metal fabrication, manufacturers face rising material costs, stricter quality requirements, and tougher global competition. Delivering high-quality components at competitive prices is no longer optional—it’s the foundation of survival and growth. While many shops have relied on plasma cutting for decades, its drawbacks—heat distortion, rough edges, and heavy consumable use—are increasingly at odds with modern customer expectations.

This article details how a European fabrication company transitioned from plasma to the HEAD1020BB waterjet cutting machine—a compact, dual-head system optimized for high-throughput metal processing. The upgrade delivered cleaner edges, tighter tolerances, lower total cost, and faster deliveries. A separate success signal came from a repeat purchase by a long-term customer in Portugal, underscoring HEAD’s reliability and service quality.

Why Plasma Cutting Was No Longer Enough

The company’s plasma setup was adequate for general steel cutting, but export clients began demanding cleaner edges, tighter tolerances, and multi-material capability. Four pain points became chronic:

• Heat-Affected Zones (HAZ): Thermal stress warped parts and hardened edges—unacceptable for stainless steel and aluminum work.

• Secondary Processing: Slag and edge roughness forced grinding or machining, increasing labor and lead times.

• Consumable Burn: Nozzles and electrodes degraded quickly, driving up operating cost and downtime.

• Noise & Fumes: Meeting stricter HSE standards raised compliance and ventilation expenses.

Why HEAD1020BB Was the Right Choice

The team selected the HEAD1020BB waterjet cutting machine for its throughput, precision, and footprint—tailor-made for job shops and batch metal parts.

Compact Work Envelope

1000 × 2000 mm table fits small-to-medium sheets and components, optimizing floor space without sacrificing capability.

Dual Cutting Heads

Two heads operating simultaneously double productivity for nests full of brackets, panels, and gussets—ideal for repeat batch orders.

Cold Cutting, No Heat Distortion

Waterjet removes material without heat. There is no warping, no micro-cracks, no discoloration, preserving metal properties.

High Precision & Surface Quality

Typical tolerances of ±0.1 mm and burr-free edges mean parts come off the table ready for assembly, eliminating grinding.

Material Versatility

Cuts stainless steel, aluminum, copper, titanium and more—plus composites and plastics—expanding service offerings without new machines.

Predictable Operating Cost

Abrasive and water are stable, forecastable inputs. Shops move from volatile torch parts to a cost-per-part model finance teams can trust.

CAD/CAM Integration

Complex geometries, small holes, micro-tabs, and common-line cutting are driven directly from digital designs for repeatable, high-yield nests.

Results After Implementation

• 50% Increase in Throughput: Dual heads slashed cycle time on batch metal parts.

• No Secondary Finishing: Smooth, burr-free edges eliminated grinding and deburring.

• ~20% Lower Total Cost: Savings came from reduced rework, fewer consumables, and stabilized planning.

• New Market Entry: Edge quality and material range opened doors to aerospace components and premium stainless furniture.

• Higher Customer Satisfaction: Faster, cleaner deliveries secured longer-term contracts.

Repeat Orders from Portugal: Proof of Trust

One of HEAD’s long-standing clients in Portugal—a metal processing company—had run a HEAD waterjet for years with stable performance and responsive after-sales service. When expanding capacity, they chose to purchase another HEAD1020BB. This repeat order validates two essentials:

• Reliability in Continuous Production: Even under heavy workloads, HEAD machines maintain accuracy and uptime.

• Customer Loyalty: Satisfied users return to HEAD when scaling operations, proving value beyond the first machine.

The Portuguese customer’s decision highlights how HEAD not only solves immediate cutting challenges but also builds long-term partnerships that support growth.

Engineering Considerations for Metal with Waterjet

Nozzle, Abrasive, and Pressure

Balancing nozzle diameter, abrasive flow, and pump pressure aligns edge finish, cut speed, and cost. Short DOE trials help lock in settings for common alloys and thicknesses.

Pierce Strategies

Lead-in arcs, ramped pierces, and off-feature start points prevent blemishes on visible edges. For thicker plate, staged pierces protect surface finish.

Nesting & Common-Line Cutting

Advanced CAD/CAM reduces traverse time and abrasive usage. Dual-head synchronization accelerates nests while preserving tolerance.

Fixturing & Support

Stable support slats and tank damping keep thin sheets flat, improving dimensional stability and micro-feature quality (slots, tabs, fine holes).

Waterjet vs. Plasma: Business Impact

• Edge Quality: Waterjet delivers assembly-ready edges; plasma typically needs grinding.

• Tolerance: Waterjet maintains tighter tolerances on stainless and aluminum.

• Materials: Waterjet handles metals and non-metals; plasma is limited to conductive materials.

• Operating Environment: Waterjet is quieter and cleaner, easing HSE compliance.

• Cost Structure: Waterjet shifts spend to predictable abrasive + water; plasma depends on wear-intensive torch parts.

Why More Fabricators Are Replacing Plasma with Waterjet

As customers standardize on burr-free edges and traceable tolerances, waterjet’s advantages compound. Shops report:

• Higher margins from eliminating secondary finishing.

• Faster delivery from stable, repeatable cycles.

• Diversification into aluminum, titanium, and composite parts.

• Better retention through visibly better quality and fewer defects.

Why Choose HEAD Waterjet

HEAD Waterjet brings 20+ years of engineering to metals, stone, glass, and composites—with an emphasis on reliability and service:

• Proven Expertise: R&D-driven systems like the HEAD1020BB tailored for metal shops.

• Global Installations: Users in 80+ countries, supported by training and lifetime service.

• Configurable Cells: From compact dual-head machines to larger gantries and robotic solutions.

Key Takeaways

• Upgrade Path: Replacing plasma with HEAD1020BB delivers immediate quality gains.

• Throughput: Dual heads drive up output without expanding footprint.

• Cost: Cutting out rework and reducing consumable dependency lowers total cost.

• Growth: Precision and versatility open higher-value markets.

• Trust: Portugal repeat purchase showcases long-term reliability and service.

Contact HEAD Waterjet

Ready to modernize your cutting cell and win higher-value work? Talk to HEAD’s engineering team about a tailored HEAD1020BB configuration, sample cuts, and an ROI model based on your parts.

Website: www.headwaterjet.net
    Email: sale2@hdwaterjet.com
    WhatsApp: +86 15942048409

HEAD Waterjet – Cutting Beyond Limits, Creating More Value for Your Business.