SpecialFocus

by Kent Kerns, Atlas Saw & Tool, LLC

nderstanding the material you are working with and the machines you are using to make cuts is the most important part of sawing plastics. This information is used to select saw blades that can achieve the cleanest cuts without chipping or melting materials. Using our knowledge and experience, we would like to share with you four categories of blades designed for different performance plastic materials. Each category has blades with different tooth geometries and tooth counts to help you succeed in your cutting process.

Acrylic blades

Cast and extruded acrylics, polycarbonate and PETG: ATB+R (Alternate Top Bevel + Raker Tooth) this aggressive tooth geometry creates a shearing action rather than a plow action to prevent blow out or chipping on the bottom of the cut, while leaving a clean finish in the field. Blade tooth count ranges from 80 to 120 teeth depending on thickness of the material. Blades with higher tooth count are better suited for thin materials, while lower tooth counts are better suited for thick materials.

Nylon, ABS, polypropylene: Modified ATB tooth geometry is designed to create less friction during the cut, allowing chips to clear the cut area without melting or rewelding to the bottom. Blade tooth count ranges from 24 to 45 depending on thickness of material.

UHMW and HDPE: Modified ATB tooth geometry creates a chip that clears very easily and is heavy enough for the dust extraction system to remove while leaving a smooth finish. Tooth count ranges from 48 to 80 depending on thickness of material.

PVC: Modified TCG (triple chip grind) with a very neutral tooth design eases into the material without creating tear out in the field or heating the chips on extraction. Blade tooth count ranges from 60 to 80.

Glass filled mechanical plastic: PCD (polycrystalline diamond) tipped saw blade with modified ATB. These blades have the same geometry required for nylon fabrication, but the glass content is very abrasive and would dull the carbide of a blade meant for nylon very quickly. PCD is a material which will withstand the abrasive nature of this material and support normal saw blade life. Blade tooth count ranges from 45 to 60.

Glass: Diamond grit blades are suited for glass cutting, these blades can have a continuous rim or can be slotted. They create a grinding action which turns material to powder rather than chip form. Glass can be very abrasive and difficult to cut using carbide tipped saw blades without damaging the material.

Dibond/ACM: Modified TCG design on this saw blade will create small fine chips on the aluminum leaving no burrs top or bottom. While the no melt side clearance will not melt or tear out leaving a perfectly clean cut. Tooth count is 100 to 140.

Virtually all materials can be cut by saws, provided the saw blade being used has the appropriate tooth count and geometry. Consulting saw blade experts on your fabrication projects will help ensure that you are selecting the right blade for your material to achieve the cleanest cuts.