CNC Routing Services vs. Waterjets: Why Routers Win for Aluminum Parts

One of our customers recently asked if our CNC routing services extend to aluminum parts—and we told him that, in fact, most of our router work at Accurate CNC is aluminum. Some manufacturers hear the term “router” and immediately think of wood or even plastic, and while we do offer routing for those materials, our primary work is on aluminum.

This customer had been struggling with waterjet-cut parts, and was searching for an alternative. We were happy to inform them that routers are a far more efficient method of cutting for many aluminum projects. Find out why routers often outperform waterjets for aluminum parts, and discover how we solved this customer’s problem. 

Edge Quality: The Critical Difference

Edge quality is perhaps the most significant difference between these two methods: Waterjet cutting employs an abrasive stream that can leave a rough edge on aluminum. In addition, when cutting thicker material, waterjet cuts tend to taper outwards (sometimes referred to as “draft”) and may lead to out-of-tolerance parts. 

In contrast, router-cut edges are clean, square, and aesthetically pleasing straight from the machine, requiring no additional finishing. This is evident in the image to the right—the contrast between the routed part on the left and the waterjet part on the right is clear. Routers can cut much tighter tolerances, as well, and we can even pre-drill holes for a customer to pin or tap later at their own facility.

The customer that we discussed earlier had been ordering waterjet-cut aluminum blanks for a drilling rig, and these parts required secondary operations on every surface due to the waterjet’s limitations. With a router, efficiency is greatly increased—our Idaho machine shop can quickly complete the machining in a single setup with tighter tolerances than their previous waterjet supplier, leaving them with minimal finishing work. 

Why CNC Routing Services Enable More Features

Waterjets are generally limited to 2-dimensional through-cuts, with the exception of rare and specialized 5-axis waterjets. Routers can do far more 2.5-dimensional machining for features like:

• Countersinks and counterbores

• T-slots

• Pockets

• Complex profiles

This ability to machine multiple features in one machine offers several advantages—by minimizing handling and setups, it reduces production time for your project. And while waterjet cutting sometimes appears more cost-effective upfront for certain projects, router cutting can offer better economics when factoring in the reduction of secondary operations and handling time.

Let Us Help You Find the Right Solution

The choice between waterjet and CNC routing services ultimately depends on your specific requirements. Routers are not ideal for every aluminum project—waterjets are typically a better option than routers for 2-dimensional steel parts that have no specific tolerance needs. However, if you’re looking for parts with tight tolerances, thick material, or aesthetic edges, routers can be perfect.

Not sure which option is best for you? No matter what capability your project entails, our CNC machine shop is happy to guide you through your best options. From laser engraving to 3D printing services, we’re always ready to consult with you on your priorities and guide you to the most efficient, cost-effective solution.

Request a quote today and see how routers can transform your aluminum parts!