Panel saws are used to cut large panels into smaller sizes.

They range from small manually-operated table saws to highly-automated numerically controlled (NC) saws.

Some production systems also have automated in-feed and out-feed mechanisms to minimise the amount of manual handling required to move sheets around.

Panel saws that are designed to cut laminated boards often have a scribing blade (also called a 'scorer') in front of the main saw blade.

It cuts slightly into the underside of the panel before the main blade cuts through the full thickness.

This helps to stop the problem of 'break-out' occurring on the underside of the board, where the surface chips out as the teeth pull through the material.

On the other side of the main blade is a riving knife.

This is a piece of steel shaped to match the curve of the saw blade.

Its purpose is to stop the material on either side of the kerf (the saw cut) from closing up and jamming the blade.

This closing action is called binding.

If a board did bind on the blade, it would have a tendency to suddenly kick backwards and possibly damage the board or blade.

Types of saws

Sliding table panel saws have a sliding table that allows the operator to push the board manually through the saw blade.

On some saws the settings are all manually adjusted, but on others they can be computer controlled.

Numerically Controlled (NC) beam saws are controlled by a computer program and designed for high volume production work.

The loading and stacking mechanisms are often automated, and the saws can cut several panels at once.

Wall saws are used in workplaces where floor space is limited.

The saw and frame are mounted to a wall, leaving the floor clear for loading and unloading the panels.

They require a special type of saw blade because they don't have a scribing blade.

Types of blades

Kitchen and bathroom manufacturers generally use tungsten carbide tipped (TCT) blades, because they are very hard wearing and suitable for cutting boards that contain glues and laminated veneers.

The tooth profiles can vary, depending on the types of boards being cut.

Square top teeth are ground square.

They cut both sides of the 'kerf', or saw cut, at the same time, so they are fast and efficient.

However, they tend to tear out the grain or chip out surface laminates at their exit point.

Alternate top bevel (ATB) teeth are bevelled in opposite directions on every second tooth.

They cut much more cleanly than square top teeth, and virtually eliminate tear out problems.

However, the leading point is easily damaged and sharpening is more difficult.

Triple chip teeth also have a different profile on every second tooth.

The 'leading' tooth has a double 45 degree corner bevel.

The second tooth, or 'raker', removes the two corners left behind by the bevels in the leading tooth.

This blade requires more maintenance, but is the most suitable for plastic laminates.