Creative Manufacturing was approached by a customer with a unique problem: 250 metal perforated ceiling tiles with acoustic backing pads that needed 200mm holes cut into the centre to allow lighting to be sunk into the tile. Sounds easy?
Using more traditional methods of cutting the customer had already caused problems. Drilling through the tiles meant that the perforated face was damaged, while laser cutting meant that the costly acoustic pads were being burnt.
The customer was looking for a method to make this simple job…simple! The previous attempts at cutting had also meant the timescales were tight for getting the job completed too.
The Test Cut
Waterjet cutting was the immediately obvious solution. The waterjet uses water pressure rather than heat to make cuts, meaning these can be made cleanly and with no heat-affected-zone (HAZ). – meaning no burn marks.
The customer transported the ceiling tiles to Creative Manufacturing for a trial cut. The waterjet was set up ready and smoothly cut the holes as needed, with no damage to the tile face or the acoustic backing pad. We were ready to go!
The Manufacture
Before the full quantity was machined, the customer came in with the lighting fitting to check that this was perfectly aligned. They also inspected the cut of the tile itself. Finally, they had a solution that worked – so they gave the go ahead for the remaining tiles to be cut. Knowing the urgency of the order, the team at Creative were able to cut the remaining tiles in just two working days, which were then collected by the customer.
The Outcome
The customer was very happy with the cuts that were made – which meant they were able to finish the job, complete with lights, to the timescales originally requested.
The waterjet can be used for a wide range of cuts – from thicker metals right down to intricate carvings. This machine uses only water and garnet abrasive for cutting, which means the waste is fully recyclable/reusable too.
