Flow Mach 500
Key Specifications
Rapid Traverse
Repeatability
table sizes
cutting area 3020
z axis travel
linear straightness accuracy
Overview
The Flow Mach 500 is Flow International's flagship waterjet cutting system, built for shops and production facilities that need the highest cutting speed, accuracy, and automation capability available in waterjet technology. Flow invented modern abrasive waterjet cutting in the 1970s, and the Mach 500 represents everything they've learned packaged into their most advanced platform.
The Mach 500 is available in five table configurations: 2020 (6.5 x 6.5 ft), 3020 (10 x 6.5 ft), 3060 (10 x 20 ft), 4020 (13.1 x 6.5 ft), and 4080 (13.1 x 26 ft). The most popular configuration is the 3020 with a 10 x 6.5 ft cutting envelope. Z-axis travel is 310 mm (12.2 in), and rapid traverse reaches 17,800 mm/min (700 ipm). Linear straightness accuracy is ±0.038 mm/m (±0.0015 in/3 ft) with repeatability of 0.025 mm (0.001 in).
The defining feature of the Mach 500 is Flow's Dynamic Waterjet XD cutting head, which provides true 5-axis motion for cutting compound angles, bevels, and complex 3D geometries. When paired with Flow's Compass contour-following technology, the Dynamic XD automatically compensates for the natural taper that occurs in waterjet cutting, producing parts with straighter edges at significantly faster cutting speeds than conventional heads. Flow claims 2-4 times faster cutting compared to conventional waterjet heads while maintaining tighter tolerances.
Pump options include the HyPlex Prime at 60,000 PSI (4,150 bar) in various horsepower ratings, and the HyperJet at 94,000 PSI (6,480 bar) with 50 HP or 100 HP configurations. The 94,000 PSI option uses Flow's HyperJet technology for maximum cutting speed on thick materials. FlowMaster software handles everything from simple 2D nesting to complex 5-axis part programming.
New Mach 500 systems typically price in the $250,000-$500,000+ range depending on table size, pump selection, and cutting head configuration. A fully loaded 4020 with 100 HP HyperJet pump and Dynamic XD head can exceed $600,000. Used units from 2017-2022 appear in the $100,000-$300,000 range. Specs sourced from Flow International published data, Sterling Machinery, Southern Fab Sales, and verified dealer listings.
Full Specifications
| Parameter | Value |
|---|---|
| Table Sizes | 2020 / 3020 / 3060 / 4020 / 4080 |
| Cutting Area 3020 | 3,050 x 2,000 mm (10 x 6.5 ft) |
| Z Axis Travel | 12 in, 24 in |
| Rapid Traverse Rate | 17,800 mm/min (700 ipm) |
| Linear Straightness Accuracy | ±0.038 mm/m (±0.0015 in/3 ft) |
| Repeatability | ± 0.0008 in |
| Cutting Head | Dynamic Waterjet XD (5-axis) |
| Pump Options | HyPlex Prime 60,000 PSI / HyperJet 94,000 PSI |
| Pump Horsepower | 30 / 50 / 100 HP options |
| Max Operating Pressure | 94,000 PSI (6,480 bar) |
| Taper Compensation | Flow Compass contour-following |
| Software | FlowMaster |
| Abrasive | Garnet (80 mesh standard) |
| Rapid Traverse Maximum | 700 in/min |
| Linear Positional Accuracy | ± 0.0005 in |
| Work Envelope | Mach 500 2020: 6’-6” x 6’-6”Mach 500 3020: 10’-0” x 6’-6”Mach 500 3060: 10'-0" x 20'-0"Mach 500 4020: 13'-1" x 6'-6"Mach 500 4080: 13'-1" x 26'-0" |
| Acceleration | 0.1 g |
| Ballbar Circularity | ± 0.0025 in |
Specifications sourced from flowwaterjet.com — verified 2026-03-28
Strengths & Limitations
Strengths
- Dynamic Waterjet XD cutting head with Compass technology delivers 2-4x faster cutting than conventional waterjet heads while producing straighter edges and tighter tolerances
- 94,000 PSI HyperJet pump option provides the highest commercially available waterjet pressure, maximizing cutting speed on thick and hard materials
- Five table size configurations from 6.5 x 6.5 ft to 13.1 x 26 ft cover everything from prototype shops to large-format production facilities
- True 5-axis cutting capability handles compound angles, bevels, countersinks, and complex 3D geometries that 2D and 3-axis systems cannot produce
- Flow's 50+ years of waterjet innovation means the deepest application knowledge base and largest service network in the waterjet industry
- FlowMaster software provides comprehensive 2D nesting, 3D programming, and material database with cutting parameters for hundreds of materials
Limitations
- Starting price around $250,000 for a basic configuration makes it the most expensive waterjet in Flow's lineup, well above the Mach 200 and Mach 100
- 94,000 PSI HyperJet pump components have higher consumable costs and shorter service intervals than standard 60,000 PSI pumps
- Large table configurations require significant floor space, water supply, and drain infrastructure that smaller shops may not have
- Dynamic XD cutting head adds complexity and maintenance requirements compared to simpler abrasive waterjet heads
- Abrasive consumption at high-pressure operation can be substantial, adding significant ongoing material costs to operation
Best For
Frequently Asked Questions
01
New Mach 500 systems range from approximately $250,000 for a basic 2020 table with standard pump to $500,000+ for larger tables with 100 HP HyperJet pump and Dynamic XD head. A fully loaded 4020 or 4080 can exceed $600,000. Used units from 2017-2022 sell in the $100,000-$300,000 range depending on table size, pump condition, and hours. The pump is the most critical component to evaluate on used waterjets.
02
The 94,000 PSI HyperJet pump cuts significantly faster than the 60,000 PSI HyPlex Prime, particularly on thick materials. However, 94,000 PSI components (high-pressure tubing, orifices, nozzles) wear faster and cost more to replace. For shops cutting primarily thin materials (under 1 inch), 60,000 PSI is often more economical. 94,000 PSI really shines on thick stainless, titanium, and hardened steel where the higher pressure dramatically reduces cut time.
03
Dynamic Waterjet XD is Flow's advanced 5-axis cutting head that automatically tilts to compensate for the natural taper that waterjet streams produce. In conventional waterjet cutting, the exit side of the cut is wider than the entry side. The Dynamic XD head angles the jet to eliminate this taper, producing parts with straight edges. Flow's Compass software continuously calculates the required tilt angle based on material type, thickness, and cutting speed, allowing the Mach 500 to cut 2-4x faster than conventional heads while producing better edge quality.
04
The Mach 500 adds the Dynamic XD 5-axis cutting head and supports the 94,000 PSI HyperJet pump, neither of which is available on the Mach 200. The Mach 500 also offers faster rapid traverse (700 ipm vs. 400 ipm on the Mach 200) and tighter accuracy specifications. The Mach 200 supports the Pivot+ 3D cutting head for simpler bevel cuts. If you're doing straight 2D cutting and don't need compound angles, the Mach 200 delivers excellent results at a lower price point.
05
Abrasive waterjet cuts virtually any material: metals (steel, aluminum, titanium, copper, brass, Inconel), composites (carbon fiber, fiberglass), stone (granite, marble, quartz), glass, ceramics, rubber, foam, and plastics. The only common materials it struggles with are tempered glass (which shatters) and certain very hard ceramics. The cold-cutting process means no heat-affected zone, no material hardening, and no toxic fumes, which is why waterjet is preferred for aerospace composites and reactive metals.
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