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The evolution of the manufacturing landscape means the demand for more complex parts, tighter tolerances, and more flexibility of production is continuously rising. The implementation of 5-axis waterjet cutting systems brought beveling, tapering, and other capabilities to the manufacturing sector; however, industries keep raising the bar.
Large castings, molded composite parts, automotive stampings, aerospace structures, weldments, pipes, and oversized fabrications frequently require cutting angles and machine reach unachievable with conventional 5-axis systems.
That’s why WARDJET came up with the revolutionary APEX-90 Waterjet Cutting Head —the most innovative 5-axis solution tailored for those manufacturers who need more from their waterjet machines.
What is the WARDJET APEX-90?
The APEX-90 is an advanced 5-axis waterjet cutting head able to cut up to 90 degrees, making the cutting stream operate in horizontal mode if needed.
Whereas traditional bevel heads focus on taper compensation and beveling of flat stock, the main purpose of the APEX-90 is accessing hard-to-reach places of parts while retaining high levels of precision.
Its innovative wrist-pivot mechanism allows you to:
- Cut up to ±90°
- Reach under flanges and overhangs
- Access cavities and recesses
- Perform 3D contour cutting
- Trim large molds and forms
- Process oversized fabrications with extended Z-axis travel
With such capabilities, the APEX-90 lets you cut parts that weren’t achievable with waterjets before.
Why Manufacturers Need More Than Traditional 5-Axis Cutting
For decades, manufacturers have used 5-axis waterjets for:
- Taper compensation
- Beveling
- Weld prep
- Chamfering
- Precision edge cutting
Though these applications are critical, many new applications require much more flexibility of cutting.
Among them are:
- Automotive oil pans
- Deep stamped parts
- Aerospace structures
- Defense components
- Large castings
- Mold trimming
- Pipe cutting
- Fiberglass structures
- Oil & gas assemblies
- Heavy equipment fabrications
All of these parts require cutting in cavities, under flanges, or through complex geometries when traditional bevel heads won’t help you.
The APEX-90 was created specifically to overcome this problem.
APEX-90 vs APEX-60: What’s the Difference?
Both the APEX-60 and APEX-90 are revolutionary 5-axis waterjet cutting solutions; however, they are designed for different types of applications.
APEX-60
Good for:
- Taper compensation
- Precision beveling
- Flat sheet processing
- Conventional 5-axis applications
APEX-90
Tailored for:
- Full 90 degree cutting
- Horizontal cutting
- Deep parts access
- Mold trimming
- Complex 3D geometries
- Large fabrications
- Vertical pipe cutting
- Overhung applications
If you only need to cut parts with bevels up to 60 degrees, the APEX-60 will be a great choice for you.
But if you need to cut at steep angles, have access to hard-to-reach places, or need to cut parts with complicated 3D geometry, the APEX-90 brings a whole new dimension of your manufacturing processes.
Industries Who Can Benefit from APEX-90
There are several industries who can get huge benefit from the capabilities of the APEX-90.
Aerospace Industry
Airframe and wing structures frequently include complex castings, formed parts, and assemblies requiring precision cuts in hard-to-reach places.
The APEX-90 allows you to machine such parts with great precision and eliminate the need for secondary operations.
Automotive Manufacturing
The automotive manufacturing industry involves many stamped and formed parts requiring trimming after pressing.
Automotive oil pan is an example discussed during the webinar.
Its complicated geometry makes this task hard to achieve with traditional cutting heads.
The unique design of the APEX-90 lets you reach inside the parts and retain tool orientation while making cuts in them.
Defense
Military parts usually involve complex geometries, thick materials, and tight tolerances.
The APEX-90 provides the flexibility required to machine such parts.
Mold Trimming
Composite and molded parts frequently require flash trimming after molding on complex mold lines.
APEX-90 excels in trimming of:
- Composite molds
- Fiberglass parts
- Plastic parts
- Thermally formed parts
Its ability to access parts inside the cavity greatly expands the possibilities of the waterjet trimming.
Oil & Gas Industry
Oil and gas processing industry involves processing of:
- Pipes
- Flanges
- Pressure vessels
- Large fabrications
The APEX-90 allows you to make cuts under the flanges and complicated cuts in pipes assemblies that are impossible to make with conventional waterjet systems.
Easy Programming with IGEMS CAD/CAM Software
No matter how innovative the hardware is, it’s not enough if it is complicated to program.
The webinar showed how much 5-axis programming has changed over the years.
APEX-90 uses IGEMS CAD/CAM software that simplifies complex 3D programming through:
- Full 3D simulation
- Collision detection
- Automated toolpaths creation
- Clearance verification
- Digital part validation
Instead of manual G-code programming—which was typical several years ago—you can now simulate a complete job before you make a cut.
Such approach helps to shorten the setup time, minimize the risks, and shorten the learning curve.
Machine Maintenance Still Simple
Despite its innovative capabilities, the APEX-90 doesn’t require some special maintenance procedures unfamiliar to many waterjet operators.
Common maintenance procedures include:
- Orifice replacement
- Nozzle replacement
- High-pressure swivel inspection
- High-pressure hose maintenance
Calibration is also an easy procedure.
In case of the accidental impact on the cutting head, it can be easily calibrated by the operator using a tooling ball.
Many people just calibrate the head monthly or after any collision.
The Biggest Misconception About 5-Axis Waterjet Cutting
One of the biggest conclusions from the webinar was that there is a misconception about the difficulty of 5-axis waterjet programming.
Indeed, it was complicated years ago.
However, nowadays it is much easier because of IGEMS simulation, digital part modeling, and automated toolpaths creation.
Expand Your Capabilities with the WARDJET APEX-90
The APEX-90 is much more than another 5-axis waterjet cutting head.
This product expands your possibilities of machining.
From aerospace and automotive to defense, oil & gas, composites, mold trimming, and heavy fabrications, the APEX-90 allows you to process applications that couldn’t be done before with waterjets or required multiple machines.
If your company is thinking about bringing complicated parts in-house, reducing secondary operations, increasing flexibility, or future-proofing your manufacturing process, the WARDJET APEX-90 will give you a competitive advantage.
Want to learn more? Contact our experts for discussion of your specific application: https://www.wardjet.com/get-a-quote/