Waterjet cutting has become the preferred fabrication method for industries that rely on precision-cut friction materials. From automotive brake pads to industrial clutch components, the demand for damage-free, high-tolerance parts continues to grow. This blog explores what makes waterjet cutting ideal for friction materials and how manufacturers can benefit from this process.

What Are Friction Materials and Where Are They Used?

Friction materials are specially engineered substances designed to generate, control, or resist motion through surface contact. They are vital in mechanical systems where controlled resistance is necessary, such as braking, clutching, or torque transfer. These materials typically combine multiple components such as fibers, resins, rubber, and fillers to meet specific mechanical, thermal, or wear-related performance requirements.

Common types of friction materials include:

• Organic composites reinforced with aramid or glass fibers
• Sintered metallic friction plates
• Ceramic-metallic hybrid materials
• Rubber-based insulators with steel backings

Industries that depend on friction materials include:

• Automotive: brake pads, clutch discs, anti-noise shims
• Aerospace: aircraft braking systems, friction cones
• Industrial machinery: press brake linings, torque limiters
• Rail transit: heavy-duty brake shoes, wear-resistant liners

Friction materials are often used in demanding environments where stability, heat resistance, and mechanical integrity are essential.

Why Cutting Friction Materials Is Technically Challenging

Cutting friction materials is not as straightforward as working with metals or plastics. Due to their layered, fibrous, and sometimes brittle structure, these materials present unique challenges in manufacturing.

Key challenges include:

1. Thermal sensitivity – Many friction materials contain resins or rubber compounds that degrade when exposed to high heat. Traditional cutting methods like laser or plasma often result in burning, charring, or material distortion.
2. Layer delamination – Multilayer materials, such as those combining steel and aramid fiber, are prone to separation or edge lifting if cut improperly.
3. Abrasiveness – Some friction composites are reinforced with hard materials like ceramic or metallic particles, which can wear down traditional cutting tools rapidly.
4. Fragility – Certain friction components are thin, dense, or brittle, making them prone to cracking or fraying at the edges if not supported properly during processing.

Precision is also critical. In braking and clutch applications, even slight inconsistencies in shape or edge quality can lead to uneven wear, noise, or safety failures. That’s why choosing the right cutting technology is essential.

How Waterjet Cutting Works and Why It’s Ideal for Friction Materials

Waterjet cutting uses a high-pressure stream of water—often mixed with abrasive particles like garnet—to slice through materials without direct contact or heat. This makes it ideal for cutting friction materials, especially those that are sensitive to temperature or consist of layered composites.

Here’s why waterjet cutting excels in this application:

Cold cutting process
Waterjet cutting generates no heat-affected zone (HAZ), which is critical for maintaining the mechanical and thermal properties of resins, rubber, or composite layers found in friction materials.

High edge quality
The precision of a waterjet allows it to produce smooth, clean cuts without burning, fraying, or delaminating the material. This reduces the need for secondary finishing operations.

Supports complex shapes
Waterjet systems are CNC-controlled and can cut intricate patterns, slots, and through-holes with excellent repeatability, which is important for brake pad profiles or clutch plate geometries.

No tooling required
Unlike die cutting or CNC blade machining, waterjet cutting does not rely on mechanical tools that wear down or require constant replacement. This leads to greater consistency across large production batches.

Material versatility
Waterjet cutting handles nearly all types of friction materials—from carbon ceramic pads to phenolic resins bonded to steel—with consistent accuracy and minimal material loss.

This combination of benefits makes waterjet the preferred method for producing high-performance friction parts at scale.

Waterjet Cutting vs. Other Methods for Friction Materials

Selecting the right cutting process is a critical decision in the production of friction materials. Each method has its own strengths and limitations depending on the material type, part geometry, and production volume.

Here’s how waterjet compares with other common cutting techniques:

Waterjet cutting

• No thermal damage
• Extremely clean edges on composite or rubber-based materials
• Ideal for layered materials (e.g., rubber-metal laminates)
• High setup flexibility and CAD-based programming
• Slightly slower than laser but more versatile in material compatibility

Laser cutting

• Very fast on thin materials
• Generates heat, which can melt or scorch rubber and degrade resin-bonded layers
• Not recommended for layered friction materials
• Lower upfront cost but limited application range

CNC blade cutting

• Suitable for softer or non-reinforced friction materials
• Tool contact may cause fraying or delamination
• Requires blade maintenance and tool replacement
• Better for simple shapes or low-volume jobs

Die cutting

• Efficient for very high-volume runs
• Requires custom tooling and press setup
• Limited to uniform shapes with minimal thickness variation
• Can deform or compress soft layers during cutting

Overall, waterjet cutting offers a superior balance of edge quality, precision, and material integrity—especially when working with mixed-layer friction materials or when high design complexity is involved.

Real-World Applications of Waterjet-Cut Friction Materials

Waterjet cutting is not just a theoretical solution—it is actively used in high-precision industries where friction materials must meet strict performance criteria. Below are examples of how waterjet cutting is applied in real-world settings:

Automotive
Brake pads, backing plates, anti-noise shims, and clutch discs all require precise shape and material integrity. Waterjet cutting ensures the composite layers remain intact, and tolerances are held tight for safe braking performance.

Railway systems
Heavy-duty brake shoes and linings used in trains must be cut in large curved profiles, often from thick, reinforced composites. Waterjet cutting allows for smooth, arc-shaped parts without warping or edge burning.

Aerospace
Landing gear systems, turbine brakes, and carbon-carbon friction discs benefit from waterjet’s ability to cut dense, high-temperature materials without introducing microcracks or surface degradation.

Industrial equipment
Brake linings for cranes, presses, and automated machinery often use specialized friction materials that require non-contact cutting. Waterjet enables efficient nesting and minimal material waste for large production runs.

Motorsport and prototyping
In racing applications, friction components must be both high-performance and lightweight. Teams rely on waterjet cutting to rapidly prototype brake pad geometries and integrate new materials without tooling delays.

Whether for mass production or custom fabrication, waterjet-cut friction materials are increasingly adopted across sectors demanding consistent edge quality, dimensional accuracy, and structural reliability.

Why Choose CSMFG for Friction Material Waterjet Cutting

CSMFG provides precision waterjet cutting services optimized for friction material applications. With advanced machinery, experienced technicians, and a deep understanding of composite materials, we deliver consistent results at scale.

Key advantages include:

Material expertise
Our team has experience handling aramid fiber composites, phenolic resins, ceramic-metallic hybrids, and multi-layer rubber-steel laminates. We understand how to cut without delamination or material failure.

Precision equipment
We operate high-pressure CNC-controlled abrasive waterjet machines capable of maintaining tight tolerances on intricate part designs. Our multi-axis platforms support flat and contoured parts.

Engineering support
From CAD file import and nesting optimization to cut-path simulation and prototype testing, our engineering team ensures efficient production and reduced waste.

Scalable production
Whether you need 10 custom pads or 10,000 high-volume parts, CSMFG’s flexible manufacturing process adapts to your schedule and inventory needs.

End-to-end quality control
We conduct dimensional inspections, material traceability, and post-processing checks to guarantee parts are ready for assembly or secondary operations.

By partnering with CSMFG, you gain a reliable manufacturing partner capable of cutting even the most challenging friction materials with speed and accuracy.

FAQ: Waterjet Cutting for Friction Materials

Can you cut laminated friction materials like rubber-bonded steel sheets?

Yes. Our waterjet cutting process is designed to handle layered materials without causing separation, heat damage, or adhesive failure.

What is the maximum thickness you can cut?

We typically cut friction materials up to 100 mm thick, depending on the composition. For multilayered or reinforced composites, optimal thickness may vary and can be confirmed during quoting.

Do you offer prototyping and small batch runs?

Absolutely. We support both low-volume prototyping and full-scale production. Our engineers can help optimize your design for manufacturability at both stages.

Will water affect the surface or bonding of resin-based friction pads?

No. Our process uses a fine, high-speed jet with proper water pressure control and support tooling to avoid soaking or damaging surface treatments or adhesive bonds.

Can you help with CAD preparation or nesting?

Yes. Our engineering team can assist with CAD import, layout optimization, and part labeling to improve material yield and reduce per-unit cost.

Contact CSMFG for Precision Waterjet Cutting Services

If your project involves cutting friction materials and you require clean edges, tight tolerances, and zero thermal damage, waterjet cutting is your best option—and CSMFG is your best partner.

We serve clients across the automotive, aerospace, industrial, and transportation sectors, offering:

• Reliable lead times and scalable production
• Expertise in cutting complex friction composites
• Advanced equipment and quality control processes
• Competitive pricing and global shipping

Ready to get started?

Request a custom quote or speak with our engineering team to see how CSMFG can support your next project.

Contact us today and let us help you manufacture better with precision waterjet technology.