Flow HyperJet 94i

$120,000 - $200,000 (pump unit only); $400,000+ as part of complete Mach 700 system Updated 2026-03-16

Key Specifications

operating pressure

94,000 PSI (6,480 bar)

pump type

Dual-intensifier (two-cylinder alternating)

pump horsepower

50 HP or 100 HP

pressure advantage

40-50% faster cutting vs. 60,000 PSI on thick materials

abrasive savings

Approx. 30% less garnet per inch of cut

pump monitoring

iP intelligent Pump predictive maintenance system

Overview

The Flow HyperJet 94i is Flow International's ultra-high pressure intensifier pump unit, generating 94,000 PSI (6,480 bar) — the highest commercially available waterjet operating pressure. Rather than being a complete cutting machine, the HyperJet 94i is a standalone pump system that can be paired with Flow's Mach 500 or Mach 700 cutting tables, or used to upgrade an existing waterjet machine from 60,000 PSI operation. At 94,000 PSI, the HyperJet 94i cuts 40 to 50 percent faster than standard 60,000 PSI pumps on thick materials, and uses approximately 30 percent less garnet abrasive per inch of cut due to the more focused, higher-velocity jet.

The HyperJet 94i uses dual-intensifier architecture, where two high-pressure cylinders alternate pumping strokes to deliver a steady, pulse-free waterjet stream. The pump is available in 50 HP and 100 HP configurations. The 100 HP version can drive a single cutting head at maximum pressure and flow, or split between two cutting heads at reduced individual flow rates. Flow's iP (intelligent Pump) monitoring system continuously tracks pressure, temperature, cycle count, and component wear indicators, alerting operators to maintenance intervals before unplanned failures occur.

At 94,000 PSI, component wear rates are meaningfully higher than at 60,000 PSI. High-pressure seals require replacement every 300 to 500 hours of operation, compared to 500 to 1,000 hours at 60,000 PSI. Orifices, nozzles, and mixing tubes also have shorter service lives. Flow recommends using only premium-grade garnet at 94,000 PSI — inconsistent or contaminated abrasive can accelerate orifice erosion dramatically. The HyperJet 94i requires specialized high-pressure tubing, fittings, and check valves rated to the 94,000 PSI operating pressure.

The HyperJet 94i is the enabling technology behind Flow's Mach 700 cutting system. When integrated with the Mach 500 or Mach 700 and Flow's Dynamic Waterjet XD cutting head, the 94,000 PSI stream produces the highest quality waterjet cut currently achievable — tightest tolerances, fastest speeds, and best edge finish on hard materials. Pump unit pricing is typically in the $120,000 to $200,000 range depending on HP and configuration, with the complete Mach 700 system (table + HyperJet) starting around $400,000.

Full Specifications

Parameter	Value
Operating Pressure	94,000 PSI (6,480 bar)
Pump Type	Dual-intensifier (two-cylinder alternating)
Pump Horsepower	50 HP or 100 HP
Pressure Advantage	40-50% faster cutting vs. 60,000 PSI on thick materials
Abrasive Savings	Approx. 30% less garnet per inch of cut
Pump Monitoring	iP intelligent Pump predictive maintenance system
Seal Service Interval	300-500 hours at 94,000 PSI
Compatible Cutting Tables	Flow Mach 500, Flow Mach 700
Compatible Cutting Heads	Dynamic Waterjet XD, standard abrasive heads
Power Requirements	480V / 60Hz, 3-phase
High Pressure Tubing	Custom 94,000 PSI rated fittings and tubing
Pump Unit Weight	Approx. 2,000-3,000 kg depending on HP configuration

Strengths & Limitations

Strengths

94,000 PSI provides the highest commercial waterjet pressure available, delivering 40-50% faster cutting than 60,000 PSI on thick hard materials
30% reduction in garnet consumption per inch of cut offsets some of the higher pump and consumable costs over time
iP intelligent monitoring system predicts seal and component wear before failures, reducing unplanned downtime in production environments
Dual-intensifier design delivers pulse-free pressure for more consistent edge quality than single-cylinder intensifier pumps

Limitations

Seal replacement every 300-500 hours at 94,000 PSI is significantly more frequent than at 60,000 PSI, adding $15,000-$25,000 per year in seal costs at high utilization
Requires premium-grade consistent garnet — low-quality or contaminated abrasive causes accelerated orifice erosion at 94,000 PSI
All high-pressure tubing, fittings, and check valves must be specifically rated for 94,000 PSI, increasing system cost and limiting interchangeability with standard waterjet components
Specialized maintenance knowledge required — not all waterjet service technicians are certified for 94,000 PSI component service

Best For

Production facilities cutting thick plate (50 mm and above) in hard materials where 60,000 PSI cutting speed is a bottleneck limiting throughput Aerospace and defense manufacturers cutting titanium, Inconel, and hardened steel alloys where maximum cutting speed reduces cost per part Shops already running Flow Mach 500 tables that want to upgrade to 94,000 PSI without replacing the entire machine High-volume waterjet operations where the 30% garnet savings at 94,000 PSI meaningfully reduces material costs at scale

Frequently Asked Questions

01 Can I retrofit the HyperJet 94i to an existing 60,000 PSI waterjet table?

The HyperJet 94i is designed to integrate with Flow's Mach 500 and Mach 700 tables. Retrofitting to a non-Flow table or older Flow machine (Mach 3, Mach 4) requires engineering evaluation and likely significant modifications to high-pressure plumbing, catcher tank depth, and cutting head compatibility. Flow's engineering team handles retrofit assessments on a case-by-case basis.

02 How much faster does the HyperJet 94i cut compared to a 60,000 PSI pump?

On 50 mm (2 in) stainless steel, the HyperJet 94i cuts approximately 40-50% faster. On 25 mm (1 in) steel, the advantage is somewhat less — closer to 25-35%. On thin materials under 10 mm, the speed advantage is minimal because traverse speed rather than jet power limits feed rate. The biggest advantage is on thick, hard materials: 3 to 8 inch steel, titanium plate, and thick Inconel where 60,000 PSI is the clear bottleneck.

03 What are the annual operating costs for the HyperJet 94i?

At two-shift operation (approximately 3,000 hours/year), expect $15,000-$25,000 in seal kits alone. Add orifice replacements, mixing tubes, high-pressure fittings, and garnet. Even with 30% garnet savings, total consumable costs at 94,000 PSI run $30,000-$60,000 per year at high utilization. This cost is justified only when the speed advantage generates enough additional revenue — typically in shops where the waterjet is a production bottleneck.

04 Is 94,000 PSI safe?

Yes, when operated per Flow's specifications and safety procedures. Flow designs the entire HyperJet system with rated safety factors at 94,000 PSI, including tubing, fittings, enclosures, and pressure relief systems. The primary safety requirements are: never exceed rated pressure, inspect high-pressure components per schedule, replace worn seals promptly, and ensure all personnel are clear of high-pressure lines during operation. Flow provides comprehensive safety training with HyperJet installations.

05 How does the HyperJet 94i compare to KMT's 90,000 PSI pumps?

KMT Waterjet offers pumps up to 90,000 PSI (Streamline SL-V 90 series). Flow's HyperJet 94i operates at 94,000 PSI — the highest commercially available pressure. In practice, the 4,000 PSI difference provides a meaningful but not dramatic speed increase over KMT's 90,000 PSI pumps. The more significant differentiator is that the HyperJet 94i is natively integrated with Flow's Mach 500 and Mach 700 tables, including iP monitoring and Dynamic XD head compatibility.