Milling, Waterjet, or Laser Cutting: What's the Difference?-copy-68770d09b8fc5
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Milling, Waterjet, or Laser Cutting: What's the Difference?
In modern machining and metal fabrication, three of the most common methods used to cut and shape materials are Milling (CNC Milling), Waterjet Cutting, and Laser Cutting. Each technique has its own strengths and limitations, and understanding their differences can help manufacturers, engineers, and procurement specialists choose the best method for their specific project.
This article explores the main distinctions among these three cutting technologies.
What is Milling?
Milling is a subtractive machining process that uses a rotating cutting tool to remove material from a workpiece. In CNC milling, the cutter moves along multiple axes to create parts with precise shapes, holes, and contours.
Materials
Works well with metals, plastics, and composites.
Best for:
Precision parts, 3D features, prototyping, and low to medium volume production.
Advantages
• High dimensional accuracy.
• Great for complex geometries.
• Can machine both external and internal features.
Limitations:
• Material waste.
• Slower for large, flat shapes compared to laser or waterjet.
What is Waterjet Cutting?
Waterjet cutting uses a high-pressure stream of water, often mixed with an abrasive (like garnet), to erode material and cut through it. It is a cold cutting process, meaning no heat is involved.
Works on nearly any material, including metal, glass, stone, ceramics, and composites.
Best for
Thick or heat-sensitive materials, or parts requiring no thermal deformation.
• No heat-affected zone (HAZ).
• Can cut very thick materials (up to several inches).
• Smooth edges, no burrs.
Limitation
• Slower than laser for thin materials.
• Higher operational costs due to abrasives and water usage.
What is Laser Cutting?
Materials
Best with metals, plastics, wood, and fabrics. Less effective with reflective or thick materials.
Best for
Thin sheet cutting, decorative patterns, signage, electronics, etc.
Advantages
• Extremely precise and fast.
• Clean, narrow kerf and high-quality edges.
• Low material waste.
Limitation
• Heat can cause warping or discoloration.
• Thickness limits (typically <20 mm for metal).**
• Can't cut reflective metals easily (e.g., copper, aluminum without special lasers).
Summary Comparison Table:
| Feature | Milling | Waterjet Cutting | Laser Cutting |
|---|---|---|---|
| Material Types | plastics | Almost all materials | Limited to non-reflective, thinner materials |
| Heat Affected Zone | Yes (minor) | No | Yes |
| Cut Thickness | Moderate | Very thick possible | Thin to moderate |
| Precision | Very high | High | Very high |
| Speed (thin sheet) | Moderate | Slow | Fast |
| Edge Quality | Machined finish | Smooth, no burrs | Clean, sharp |
| Cost | Medium | High | Low to Medium |
Conclusion
Choosing between milling, waterjet, and laser cutting depends on your material, part complexity, tolerance requirements, and budget. If you need complex 3D features, CNC milling is ideal. For thick or heat-sensitive materials, waterjet cutting is the safest bet. For fast and precise sheet cutting, laser is often the best solution.
Still not sure which process suits your needs? Contact our machining experts — we'll help you determine the most cost-effective and technically appropriate method for your project.
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