Whether the challenge calls for remodeling, restoration, or, of course, new construction, consumers want quality, uniqueness and durability. No longer are they satisfied with traditional materials used in architectural and interior designs. More and more, consumers are demanding exquisitely detailed creations using hard metals, stone and tile. Waterjet technology has proved to be the salvation for many companies. Seeking to satisfy consumer demand, cutting shops, have adopted the technology and are now able to realize the dream of any architect, engineer or designer quickly, efficiently and economically. Waterjet Cutting: Precision and Power The technology, simply defined, is a computer-controlled, high-speed erosion process. Water, traveling at speeds up to Mach 2.5 and focused through a small orifice, literally carves its way through any material. Waterjet applications can range from the delicate task of cutting cake to the arduous task of penetrating armor plate. In between lies the palette of materials commonly used by architects and interior designers, including steel, aluminum, brass, glass, wood, marble, granite and ceramic tile.

Not limited by the archaic constraints of conventional cutting technology, professionals can allow their imaginations to soar. Classic floor designs, interior and exterior artwork, custom countertops, marble pillars and arches are a few of the typical creations. Multidimensional projects are also made possible by the extraordinary flexibility of this technology.

Among those who have embraced the new technology is Pat Spence, of Cut All Waterjet Cutting, Taylor, Mich. Spence takes pride in some of the elaborate designs he has created from stone.

He particularly enjoys the appreciative feedback he often gets from installers.

"Originally," he explains, "many installers looked at the design and saw a formidable task ahead of them. However, they quickly realized that the precision of the waterjet cut allows pieces to fit easily together. Most installers are quick to comment on that."

Stunning Church Renovation

An exacting fit is exactly what was needed for a project Spence completed recently in Westland, Mich. For the newly built Sts. Constantine and Helen Greek Orthodox Church, parishioners wanted their treasured symbol of a two-headed eagle emblazoned into the floor before their altar. Once a symbol of the union between church and state under the Eastern Roman Empire, the eagle was re-created in a marble floor motif. The designer selected red marble to depict the double-headed eagle, encircled by a swirled red-marble swirled border. The red marble was accented using a white marble background and bordered by concentric circles of dark green and gray marble. The eagle measured roughly 5' x 5' and nested inside a 12' x 12' rectangle of green, white and gray marble.

The eagle medallion rests at the foot of the altar, which is also rendered in gray marble. A semicircle of several marble steps leads up to the altar. A long aisle down the center of the church, also done in matching squares of gray marble with a green and white border, directs attention to the focal points of the altar and medallion. The overall impressions is one of grandeur and solemnity.

Waterjet technology was crucial in creating this art-work, as well as in making it economically affordable. The curves that constitute the eagle, as well as the surrounding swirls, would be difficult, if not impossible, to exact from marble by other means. The tolerances typically provided by traditional marble-cutting methods are not precise enough to create the quality seams that exist in this piece. Without precision tolerances, a design such as this could become an installer's nightmare.

Waterjet technology does more than make this kind of precision possible--it makes it affordable. The waterjet process is fast, is less labor-intensive than others, less capable methods, and conserves valuable material resources. The original design is easily scanned into a computer, and with minimal programming, the computer is ready to direct the cutting heads. Pieces can be nested so that there is minimal waste of material. The latest software generates the optimal placement of nested parts, assuring even greater savings in the cutting process.

The Secret: Controlled Erosion
All edges are made using the simple principle of erosion. A relatively easy phenomenon to understand, it also implies additional benefits. Controlling the speed of erosion allows the operator to control the final quality of the edge cut. In the case of Sts. Constantine and Helen church, a smooth edge was needed to achieve the tight tolerances allowed between the pieces, and to create a smooth edge for a more elegant-looking design.

Erosion also avoids most of the cracking and chipping that typically occurs in marble when high-impact cutting methods are used. Waterjet technology leaves a cut piece accurate and intact. Economies are readily realized in the amount of material saved during the cutting process, in the labor saved as a result of a reduction in the number of material setups, and the sheer number of pieces that do not have to be recut to meet specifications.

Whatever the application--creating something new, or revitalizing something old and treasured--waterjet technology can meet the challenges posed by a today's needs, restrictions and exciting array of materials.