Panel saws

A panel saw cuts large sheets of plywood, MDF, particleboard and melamine into accurate rectangular parts. Sliding table saws suit workshops that cut a mix of panels and solid wood with a skilled operator; beam saws suit cabinet and furniture plants that cut from optimised lists, often in stacks, with less handling.

How the two main types work

Sliding table saw

The sheet sits on a long carriage beside the blade and the operator pushes it through, using a rip fence for widths and a crosscut fence on the carriage for lengths. A small scoring blade ahead of the main blade scores the underside so laminated faces do not chip. On the Altendorf F 45, rise, fall and tilt from 0 to 46 degrees are motorised, and the cutting height is corrected automatically when the blade tilts. The MARTIN T66 tilts right to 46 degrees and varies blade speed steplessly from 1,000 to 5,000 rpm, so speed can be matched to the material.

Beam saw

A beam saw works the other way round: the panel stays still and the blade moves. A program fence with clamps grips one sheet or a stack and pushes it to each cut line, a pressure beam comes down, and a carriage with main and scoring blades travels under the beam. Air cushion tables in front let the operator turn strips for the crosscuts. On the HOMAG SAWTEQ S-100, the program fence and saw carriage each move at up to 60 m/min. The SCM gabbiani s switches each air table section on only where it is needed, so cut parts parked on the tables do not slide off.

How to choose: the specs that matter

Cutting length

Cutting length must exceed your longest sheet plus the trim cut. A 4 x 8 ft sheet is 2,440 mm long and a 5 x 10 ft sheet about 3,050 mm. A 3,200 mm beam saw covers both; on a sliding table saw, a 3,000 mm carriage handles 4 x 8 ft sheets and a 3,300 mm or longer carriage leaves room for 10 ft stock. Longer machines earn their floor space only if you buy oversize panels or cut long solid wood.

Blade projection and stack height

On a beam saw, blade projection sets the thickest stack you can cut. On paper, 65 mm covers three 19 mm sheets and 115 mm covers five with some margin; the maker's data sheet gives the real maximum once clamps and scoring are allowed for. On a sliding saw, projection matters for thick solid wood and for bevel cuts, where the blade loses height as it tilts.

Scoring and setup

Both types use a scoring saw for chip-free melamine and laminate. HOMAG offers electric scoring saw adjustment on the S-100, and SCM's SAW SET device adjusts the tools electronically on the gabbiani s, which shortens setup after a blade change. On the sliding saw side, the F 45 can be configured with Altendorf's patented crosscut fence with integral length compensation.

Software and cutting lists

Beam saws run from cutting lists. The S-100 uses HOMAG's CADmatic 5 software on a 24 in multi-touch screen, with a label printer as an option; SCM's Maestro active cut keeps a panel stock list and handles off-cut restocking. Check that your cabinet or design software can send lists to the saw directly, and whether optimisation software is included in the quote.

Safety

CCOHS guidance for table saws calls for a guard with a riving knife and anti-kickback fingers, a blade set no more than about 3 mm (1/8 in) above the work, a push stick when the fence is closer than about 15 cm (6 in) to the blade or the piece is shorter than about 30 cm (12 in), and a stance out of the line of kickback. Altendorf's HAND GUARD system watches the cutting zone optically and, in a dangerous situation, slows the saw unit and stops the blade. A beam saw keeps the blade under the pressure beam, and HOMAG lists all-round safety equipment as standard on the S-100.

What your plant needs

• Power. Main motors from 4 kW to 18 kW, plus scoring motors and, on beam saws, fence and carriage drives, all on three-phase supply. See 600 V power for imported machines if the saw is built for another market's voltage.
• Extraction. Connect both the blade guard and the under-table hood; CCOHS recommends proper sawdust exhaust for each operation and notes that wood dust is classed as a carcinogen.
• Floor. A beam saw needs its air tables in front and a clear infeed area behind for full sheets or a lift table. A sliding saw needs carriage travel on both sides of the blade.
• Air. The air cushion tables on the gabbiani s have their own blower motors; clamps and other units may also use shop air, so take the figure from the installation data.

Running costs and consumables

• Blades. Main and scoring blades need regular sharpening, and abrasive boards shorten the interval. Keep a spare set so the saw keeps running while one is at the sharpener.
• Setup after blade changes. Realigning the scoring blade takes time on manual machines; electronic adjustment shortens it.
• Material yield. On a beam saw, optimisation software and off-cut management decide how much of each sheet becomes parts.
• Labour. A sliding saw ties an operator to every cut; a beam saw frees time for stacking, labelling and sorting.
• Extraction and power. Collector filters, waste handling and the running power of the motors.

Who buys panel saws

Cabinet, furniture, closet and millwork shops cut most of their parts on panel saws, and many keep one beside a CNC router for plain rectangles such as backs, shelves and fillers; see CNC router vs panel saw. Sliding saws also serve joiners and shops that cut solid wood and plastics. For a side-by-side decision between the two families, read sliding table saw vs beam saw, and expect faster cutting to move the bottleneck to the edge bander. The cabinet shop machine guide covers which machine to buy first.