Using abrasive waterjets and EDMs in tandem can provide a one-two punch that increases throughput of small, metal parts less than about 1-in. thick. Combining the processes also decreases machine wear, reduces scrap, and shapes parts from less raw material. A good example comes by first roughing-out parts with a waterjet when cutting materials such as aluminum. In fact, doing this let one company slash 72% of the time it usually took to cut parts. Roughing with a waterjet left just one skim pass for the wire EDM. Another advantage: Cutting as much of the part as possible before EDM reduces the amount of aluminum sludge in the dielectric fluid, which also lengthens fluid filter life.

Waterjet software nests part shapes to maximize material usage in rough fabrication. Operators identify material in the software, number of pieces, and lay out parts on one or more sheets. Machines such as the two or three-axis Classica, four-axis Suprema, and five-axis Evolution waterjets are intended to work with EDM and thus feature a solid-base construction and special tooling tables.

Lastly, combining both processes gives shops a way to quickly produce prototype or demonstration parts. This is helpful because many companies practically give away the parts while promoting new products such as implantable devices.