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In today’s fast-paced automotive and industrial manufacturing environments, flexibility and efficiency are more important than ever. Manufacturers of molded parts, automotive interiors, insulation panels, carpet liners, and textile-based components are facing constant design changes, shorter product life cycles, and increasing cost pressures. Traditional die cutting methods, while proven, often struggle to keep up with these evolving demands.
That’s where the Alliance Automation, LLC. - Flint, MI Four Post Gantry Robotic Waterjet System comes in. Engineered and built in the USA, this system provides a production-ready solution that combines robotic automation, high-pressure waterjet cutting, and flexible programming into one streamlined package.
Ideal for larger parts and for customers who require fast cycle times with high production volumes - the Four Post Gantry Waterjet System features four inverted robots—either the Yaskawa Motoman GP25 robots or ABB IRB2600 robots — mounted overhead on a robust gantry frame. Hanging the robots inverted allows them to cut from above downward, maximizing part access and simplifying fixture design.
A 72" x 120" fixture base (larger available) with precision locating pins ensures fast, repeatable fixture placement. Customers can also configure the system with a shuttle table or a rotary turntable, allowing continuous loading and unloading to minimize downtime and boost throughput.
The system cuts 3-dimentional parts with pure water at 50,000–60,000 psi—no abrasive required—making it particularly well-suited for cutting soft-trim and textile-based molded parts. Typical applications include:
Global OEMs are pushing automakers and Tier suppliers to adapt quickly to shorter product life cycles, more frequent design refreshes, and increased use of advanced materials. For soft-trim and textile-based parts—headliners, wheel arch liners, trunk liners, and insulation panels—this creates a bottleneck for suppliers still relying on fixed dies.
Every design update means retooling, re-engineering, and absorbing costs that eat into margins. Waterjet cutting, by contrast, provides:
In short, robotic waterjet systems align perfectly with the industry’s move toward flexible manufacturing.
Alliance Automation provides features with the customer in mind. Ease of use, adaptability and the ability for customers to take true ownership of their equipment.
Additional option of a 25HP vacuum system, which is extremely powerful, securing parts to the table while simultaneously removing water, cutouts, and debris from the cutting process. This improves edge quality, reduces secondary cleanup, and ensures consistency from part to part.
The four post gantry waterjet can be configured with a fixed table, shuttle or turntable. A shuttle can be used with two presses feeding a single waterjet system and a turntable is ideal for decreasing cycle time by eliminating operator load/unload times.
Alliance Automation is an authorized integrator and has experts in both Yaskawa Motoman and ABB robots. These robots are both programmed with speed independence and offer high path accuracy. The programmed path and playback both are now closer than ever. A part programmed with a speed of 100mm/sec can now be sped up without affecting the path. This makes programming easier while reducing cycle times and improving accuracy.
Yaskawa Video: https://www.youtube.com/watch?v=esYWGlz351E
ABB Video: https://www.youtube.com/watch?v=_EQ2Z6RtTjk
One of the system’s greatest strengths is its flexibility in programming. Customers will have access to a host of programming tools.
Alliance Automation is an authorized distributor of RobotMaster® CAD to path offline programming software. This software is easy to use and incredibly powerful. Programs that once took days, now take a couple of hours to implement. Alliance Automation systems are set-up and ready to be used with Robotmaster.
At the heart of the system is a Hypertherm intensifier pump, available in 50HP, 75HP, and 100HP configurations. Hypertherm pumps are widely regarded in the industry for their reliability, long service life, and efficient energy usage, giving manufacturers confidence in 24/7 production environments.
Hypertherm intensifier pumps offer patented AIT (advanced intensifier technology). This technology includes a host of design advantages to increase seal life and improve the ease of maintenance. For instance, the center section of this pump has an average life of 12,000 hours between rebuilds!
Alliance Automation also offers comprehensive training packages, enabling customer teams to program and maintain the system independently if desired. This not only reduces reliance on outside integrators but also empowers manufacturers to quickly adapt to new part designs and production changes.
Alliance Automation is proud to design and build these systems in the United States. While low-cost imports from overseas—particularly from China—continue to try and enter the market, many lack the durability, service, and integration expertise required for sustained success in production environments.
By choosing a USA-built robotic waterjet system, manufacturers gain:
The automotive industry is moving toward lightweight materials, advanced composites, and soft-trim innovations. Flexible cutting solutions like the Four Post Gantry Waterjet System help Tier 1 and Tier 2 suppliers meet OEM demands while keeping operations lean and agile.
With over 20 years of experience in robotic waterjet integration, Alliance Automation continues to set the standard for precision cutting, flexible automation, and American-made reliability.
If your operation requires a proven solution for cutting molded parts with speed, accuracy, and adaptability, the Four Post Gantry Robotic Waterjet System is engineered to deliver.
Contact us for more information!
https://www.allianceautomationllc.com/robotic-waterjet-systems
Learn more about how Alliance Automation can help move your business forward.
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