OMAX water jet technology becomes indispensable in the aerospace industry

In the rapidly evolving aerospace industry, the demand for precision, efficiency, and innovative manufacturing solutions has never been greater. ThyssenKrupp Aerospace, a leading player in this sector, recognised the need to adapt to the challenges posed by complex materials and intricate component designs. To remain competitive and meet the rigorous standards required by aerospace applications, the company sought a cutting-edge solution that would enhance its operational capabilities. This case study explores how ThyssenKrupp Aerospace successfully implemented OMAX abrasive water jet technology, allowing them to streamline their manufacturing processes, improve turnaround times, and maintain high-quality standards in the production of aerospace components. 

About ThyssenKrupp: ThyssenKrupp is a diversified industrial group and a leading international industrial and technology company, employing around 100,000 people across 48 countries. In the fiscal year 2022/2023, ThyssenKrupp generated sales of €38 billion. As of October 1, 2023, the company streamlined its operations into five key segments: Automotive technology, decarbon technologies, materials services, steel Europe, and marine systems. 

With a strong foundation in technological ability, ThyssenKrupp develops cost-effective and resource-friendly solutions to address the challenges of the future. The company invests heavily in research and development, with approximately 4,000 employees working across 75 global locations. These efforts focus on critical areas such as climate protection, the energy transition, digital transformation in industry, and the mobility of the future. 

The organisation pursues ambitious climate protection targets and continually optimises its energy and climate efficiency. By using its diverse capabilities across relevant value chains, ThyssenKrupp plays a significant role in advancing its customers’ green transformation initiatives. More about ThyssenKrupp 

Challenge 

In the competitive aerospace industry, precision and efficiency are paramount. ThyssenKrupp Aerospace, based in Washington State, USA, faced significant challenges in meeting the demands of a dynamic market that needed the near-net shaping of complex aerospace components. The company’s operations relied heavily on cutting titanium and aluminium materials, often up to 6 inches thick. Traditional machining methods pose several limitations, including lengthy processing times, heat-induced warping, and the inability to handle a variety of materials effectively. With increasing project requirements, ThyssenKrupp needed a cutting solution that would enhance efficiency while supporting the high standards required in aerospace manufacturing. 

Solution 

To address these challenges, ThyssenKrupp Aerospace turned to OMAX water jet technology. The company integrated eight OMAX water jets into their operations, specifically the OMAX 2652 JetMachining Center, known for its versatility and precision. These water jets utilise a combination of high-pressure water and abrasive material, allowing them to cut through various materials, including tough composites like carbon fiber and Kevlar. 

The OMAX software is another critical part of this solution. Its ease of use enables operators to quickly program complex cutting paths, allowing for rapid adjustments and minimising downtime. This flexibility means that a single water jet can transition seamlessly between cutting applications, whether for aerospace components or other industries, such as jewellery making. 

Implementation 

The implementation of the OMAX waterjets at ThyssenKrupp Aerospace involved a strategic approach to integrate the new technology into their existing workflows. The company invested in training their operators on the OMAX software, ensuring they could use the full capabilities of the machines. 

One of the key factors in the successful integration was the ability of the OMAX waterjets to handle thick materials without the need for special tooling or considerations for heat buildup. This feature drastically reduced the time spent on setup and allowed for quicker turnarounds on projects. The ability to cut materials without melting or generating hazardous fumes eliminated the need for costly air handling systems, further streamlining the operations. 

The facility reported that single cuts on 4 to 6-inch titanium and aluminium pieces could take several hours, but the precision and clean edges achieved by the waterjets minimized the need for additional finishing processes. The OMAX waterjets have become indispensable in the company’s ability to support quick turnaround times, fulfilling the rigorous demands of the aerospace sector. 

Conclusion 

The partnership between ThyssenKrupp Aerospace and OMAX demonstrates the transformative impact of water jet technology in the aerospace industry. By using the capabilities of OMAX abrasive water jets, ThyssenKrupp has improved operational efficiency, enhanced precision in cutting complex materials, and kept the high standards needed for aerospace manufacturing. The success of this implementation underscores the versatility of OMAX water jets, which can adapt to various applications, proving that this innovative technology can meet the diverse needs of industries far beyond its traditional applications. 

As aerospace projects continue to evolve, ThyssenKrupp Aerospace stays committed to utilising OMAX technology to push the boundaries of precision manufacturing, ensuring they are still competitive in an
ever-changing market. 

Are you looking for a solution to meet the demanding precision and performance standards of aerospace manufacturing?

Get in touch with our experts to find out how OMAX water jet technology can improve your production methods, providing unparalleled accuracy and effectiveness customised for your aerospace requirements. Contact us for a discussion and uncover the revolutionary possibilities of our offerings.