Waterjet cutting case study: Aerospace aluminium

Monday July 13, 2026

Maximising material yield in aerospace grade aluminium

Client Sector: Aerospace
Material: 178mm thick aerospace grade aluminium
Billet size: 178mm x 178mm x 1100mm

The Challenge

An aerospace customer of our waterjet cutting service required a 178mm thick aluminium to be profiled with complex longitudinal cuts. These cuts would produce two oversized blanks ready for final CNC machining. Traditionally each finished component required its own billet. By utilising waterjet cutting for the roughing out, material consumption was significantly reduced. The challenge was clear:

Could a single billet be processed to produce two machinable blanks without compromising accuracy or quality?

Model showing the final CNC machined component inside the final blanks provided to the customer

The final two blanks sat on top of each other showing the second waterjet cut

Final blank ready for CNC machining

Waterjet cut material providing two final blanks

The solution

Using waterjet cutting combined with our Dynamic® waterjet cutting head technology, Hydromar developed an innovative cutting strategy that transformed what was previously waste material into valuable stock. Rather than removing large volumes of material as swarf, the billet was profiled to create two oversized components from a single block, significantly increasing material utilisation.

Process development

Trial and validation

Before production commenced, a test cut was carried out to measure the natural waterjet taper produced when cutting through 178mm of aluminium. The results showed an uncorrected taper of only 0.67mm over the full depth of the waterjet cut.

Our Dynamic® waterjet cutting head allows us to utilise taper / kerf correction. By applying a compensation factor through the Dynamic® waterjet cutting head software, the taper was eliminated, enabling accurate, parallel-sided profiles throughout the entire thickness.

Cut 1 – Material recovery

The first, full-depth cut, removed the material above the profile line. Previously, this material would have become waste swarf during machining. Instead, it was recovered as usable aerospace-grade stock suitable for manufacturing smaller components, immediately improving material efficiency and reducing waste. The Dynamic® waterjet cutting head automatically adjusted the cutting parameters, maintaining dimensional accuracy across the entire profile.

Cut path to split the initial billet into three offcuts and the blank ready for the next step

Cut 1 – Producing blank for next stage and three off cuts

Photo showing the blank and three off cuts after the first waterjet cut

Cut 2 – Producing two blanks for machining from one blank

Following the first operation, the stock was rotated through 90 degrees and a second, common-cut profile was completed. This operation required specific programming to compensate for varying material thicknesses, ranging from the full 178mm section down to approximately 83mm at the thinnest point.

Cut path to split the previous blank into two blanks for final machining

Cut 2 – Splitting the waterjet cut blank to produce two blanks for machining

Photo showing the previously cut blank after being waterjet cut to produce the final two blanks for machining

The result

Material yield doubled
Two machinable blanks produced from a single billet
Significant reduction in raw material costs
Recovered offcuts, creating reusable stock rather than swarf
Reduced machining waste and improved sustainability
Reduced machining time, producing further savings

Customer benefit

By combining innovative programming with advanced waterjet cutting technology, Hydromar delivered a solution that not only met the customer’s technical requirements but also dramatically improved material utilisation.

Photo showing the final waterjet cut blanks and offcuts

If you have a ‘problem’ like this, then talk to the ‘problem solvers’ at Hydromar.