Above: Imperial Metalwerks can switch between cutting materials ranging from steel, aluminum, plastic, rubber, and other materials without complicated setups or downtime.

February 2019 - After years spent working under someone else, Dave Baran opened his own shop, Imperial Metalwerks Inc. in Auburn, California. “After building the foundation to the company, [my] next step was to get a versatile waterjet cutter,” Baran says. “I looked at multiple manufacturers but it was Flow that showed up to my door the day after I made my initial call.”

Baran purchased the Flow Mach 200 in April 2018. “At the time, no one had one and I was the first to install it outside of Flow’s demonstration machines,” he recalls. “After getting used to the machine, it’s been a seamless process ever since.”

Since installing the Mach 200, Imperial Metalwerks has been busy. The shop frequently cuts parts for handrails, gates and joinery pieces. “Previously we would have had to weld together pieces and then grind the joints,” he says. “Cutting with the waterjet results in less distortion and that means less effort to hide joints or provide secondary processing. The cut pieces are clean and fit well.”

Baran has been able to apply a woodworker’s dovetail joint, which leaves no seam unhidden, and has pulled it off with precisely cut metal pieces. “To fit a dovetail joint using metal is pretty difficult to do well—it’s an impressive result,” he says.

The Flow Mach 200 uses the Pivot+ cutting head, which is capable of taper compensation and 5-axis waterjet capabilities and 60 degrees of tilt in a compact design that allows for three sides of access for efficient loading and unloading of materials.

User friendly

The waterjet’s design allows anyone to catch on quickly. “My wife is a teacher and she was able to figure it out and run the machine on the weekends,” Baran says. “Without having any fabricating experience she was able to pick a program, load it up and get it running.”

The Mach 200 uses intuitive software, which allows users to bring in their own files or use Flow’s software to draw it. “You can path a complicated part with one button,” says Evan Washington, application specialist, Flow International Corp., Kent, Washington. There is no need for the user to memorize or reference a chart for feed rates on different materials and thicknesses. The software includes an index with more than 100 materials to choose from. The operator need only select the thickness of the material to be cut.

The software helps bridge the growing gap as a result of increased labor shortages. “I find that all my customers appreciate smarter and easier-to-use software,” Washington says.

Many of Flow’s customers run multiple waterjets with strict adherence to hiring and training procedures, but the majority of its waterjet machines are installed at small businesses like Imperial Metalwerks. “Some have only ever used hand tools in their shops,” Washington adds.

The three-person crew at Imperial takes turns operating the Mach 200. “Whoever works on it depends on the day—it’s interchangeable. With the basic knowledge of safety first, any of us can work it,” Baran says. “It’s a plug-and-play process. No matter what the material, whether steel, aluminum, plastic, rubber—running the machine stays the same and we can go from job to job without wasting time.”

Tailored to fit

The Flow Mach 200 series of waterjet is configurable with the Pivot+ cutting head, which is capable of taper compensation and 5-axis waterjet capabilities and 60 degrees of tilt in a compact design that allows for three sides of access for efficient loading and unloading of materials.

“We are very fortunate at Flow, we invented [waterjet] technology and have the ability to put together packages tailored specifically for your application,” says Washington. “Whether you prefer an open bridge or gantry design, direct drive or intensifier pump, we offer it all with a number of cutting heads and additional options.

Imperial Metalwerks cuts intricate designs adhering to customer requirements and tolerances.

“When we first meet with a customer we like to walk them through how waterjets work, and their capabilities,” he continues. “We learn the intended use of the waterjet, understand the customer’s business and existing equipment, future equipment purchases, [as well as] what types of materials and sizes they work with. We often find other uses for the waterjet in our customer’s facility that could potentially save time and money. We also discuss cutting heads and potential operating hours. This helps us narrow down the configuration to the machines and pumps that will solve their current needs and provide them with options that fit their long-term goals.”

Pushing limits

Imperial Metalwerks recently tried cutting 3-inch-thick steel. “It was flawlessly accurate and we were really excited about that for our automotive customers,” Baran says. “The customer was blown away by how clean and straight it cut the thicker material. We’re always looking to push that envelope—even if it’s something people say can’t be cut.”

In addition to steel and aluminum, Baran cuts brass, copper sheet, “and any other materials that come through the door,” he says. “A customer brought copper in because they couldn’t cut it with their laser. We could do it.”

Getting abrasive into the 900-pound hopper can also be performed by any employee, he adds. “It’s just an overall easy machine to navigate. If you’re mindful to stay out of the jet stream’s way and not to stand too close, you’re going to be fine.”

Imperial Metalwerks offers drafting in house. “Customers can send in CAD or almost any file and the software works with the waterjet, It’s the plug-and-play and we’re able to cut whatever file they bring in or draft it ourselves. I’ve had customers come in with sketches on cocktail napkins, asking us how to help them fit together the puzzle. It’s a grab bag of everything that comes through our doors and we can cut it.” MM