Are PCD Blades Right for Your Shop?

PCD Saw Blades can Outperform Carbide

Diamonds Can Be A Woodworkers Best Friend!

Regardless of whether you’re a small to medium sized cabinet shop or a large production facility, if you haven’t considered PCD (polycrystalline diamond) saw blades perhaps now is the time!  Materials such as particle board, MDF, laminates and solid surface are all excellent candidates for diamond saw blades. When comparing Diamond v. Carbide, depending on the machine and the material application, diamond saw blades can outperform carbide by a ratio of 30-50 times!  

Over the years, diamond saw blade production has improved tremendously and as an industry, we’ve seen steady price reductions.  With the multitude of suppliers now offering PCD tooling it’s important for you, the discerning buyer, to know what you are purchasing and compare apples to apples in the shopping process.  There are several important factors to think about when considering the purchase of a PCD blade. Simply putting diamond tips on a carbide saw body, for instance, might result in the blade body wearing out long before the tips will. The PCD blade tip height plays a big role in price. A 300mm x 72 tooth blade with a 6mm high tip, for instance, will cost more than the same blade with a 4mm tip. Here’s the catch: The latter will only be serviced a maximum of 3x and it will have to be retired, whereas the 6mm tip blade will usually yield 7-8 resharpenings. Another important point is to know upfront what the typical cost to sharpen is.

Here is an example use case from one of our customers:
A cabinet manufacturer located in Florida and utilizing a Holzma Model 430 beam saw found they were changing their carbide main and scoring blades on a daily basis! At the beginning of 2016, they invested in a 450 mm PCD main and 180 mm PCD scoring saw. The diamond saw blades were put into production on January 4th and were removed from production for sharpening on April 7th, 69 production days! Needless to say, a second diamond set was ordered.

From replacing carbide saw blades on a daily basis to running 69 production days on one PCD blade set! Considering the cost of a diamond set can be 10 – 12 times the price of a carbide set it leaves little doubt that in this case, the initial cost factor is far outweighed by the extended tool life most certainly justifying the investment. In addition, this doesn’t take into consideration the cost of having to maintain the huge number of carbide sets needed for rotation purposes or the machine downtime savings created. 

There is one caveat: Diamond tooling provides the best performance when cutting homogeneous material. If you are cutting particleboard today and solid surface material tomorrow, then you should probably stick to carbide. When deciding whether to switch, be conservative in your cost analysis and base your justification on the diamond tool lasting 25x longer than carbide or, simply give us a call at 800.544.8436 to discuss and make sure it’s the right choice for you.

Diameters from 2 to 40 inch

Kerfs from 0.050 to  0.750 inch

Call us for the size you need

CDTooling also offers complete sharpening service

Quick turn around time.

State of the art equipment set these blades apart from other brands.

Extraordinary wear resistance. 

Longer tool life

Increased machine up-time

Superior work piece quality

Consistent surface finishes.

With a longer tool life and enhanced product quality,

The best solution for your difficult to machine materials.

Call us today 716 791 6197

CDTooling can supply any type of saw blade to match your operation. 

We are able to provide cutting tools for the plastic, woodworking

non-ferrous, composite, framing, and ferrous cutting industries

Are you tired of struggling with cutting hard materials like hardwood, laminate, or even metal? Look no further than PCD saw blades, your secret weapon for effortless precision cuts. PCD, or Polycrystalline Diamond, is a revolutionary material that combines the hardness of natural diamonds with the durability of industrial-grade carbide. This unique combination makes PCD saw blades the go-to choice for professionals in both bespoke and mass production.

Whether you're a seasoned woodworker or experimenting with new techniques and materials, PCD saw blades will elevate your cutting experience to a whole new level. Say goodbye to chipped edges, jagged cuts, and frustratingly slow progress. With PCD saw blades, you'll achieve clean, smooth cuts every time, saving you time and energy on your projects. So, if you're ready to take your cutting game to the next level, invest in the power of PCD saw blades and unlock a world of effortless precision.

What are PCD Saw Blades?

PCD saw blades are cutting tools specifically designed to handle the challenges of cutting hard materials. PCD stands for Polycrystalline Diamond, a synthetic material created by sintering diamond particles with a carbide matrix. The result is a cutting edge that combines the hardness and durability of natural diamonds with the toughness and heat resistance of carbide. PCD saw blades are made by bonding PCD tips to the cutting edge of the blade, providing an incredibly sharp and long-lasting cutting surface.

This type of diamond tool tipping can also be referred to as DP.

One of the key advantages of PCD saw blades is their ability to maintain their cutting edge for a significantly longer time compared to traditional saw blades. This means you can make more cuts without having to constantly replace or resharpen the blade, saving you both time and money in the long run. This key feature is what makes PCD saw blades so coveted by large manufacturers. Additionally, PCD saw blades are known for their exceptional heat dissipation properties, reducing the risk of blade dulling or warping due to excessive heat buildup during prolonged use.

In terms of design, PCD saw blades come in various configurations to suit different cutting applications. From general-purpose blades for everyday use to specialized blades for specific materials like laminate or metal, there is a PCD saw blade available for every cutting need. With their superior cutting performance and versatility, PCD saw blades have become a staple in industries such as woodworking, construction, and metal fabrication.

Additionally, companies like Leitz are always happy to create custom modifications, this means we can ensure that any PCD tooling is appropriate for your workpiece and desired result.

Advantages of PCD Saw Blades

PCD saw blades offer a multitude of advantages that set them apart from their conventional counterparts. Most sawblades are made from high speed steel or carbide. Carbide is a notoriously strong cutting material but even carbide is outperformed by diamond in most applications.

Exceptional Cutting Performance: PCD saw blades deliver unparalleled cutting performance, thanks to their diamond-infused cutting edge. The hardness of the PCD tips allows for precise and clean cuts, while the carbide matrix provides the necessary toughness and durability to withstand the rigors of cutting hard materials. This means PCD enabled a high quality finish on the toughest of materials.

Extended Blade Life: Due to their superior hardness and wear resistance, PCD saw blades can last longer than traditional saw blades, with common estimates at 25 times longer. This longevity translates to fewer blade changes, less downtime, and increased productivity. Having a blade that can withstand heavy use is a game-changer and generally lowers the overall tooling cost and reduces the need to rework a damaged workpiece.

Reduced Friction and Heat Buildup: PCD saw blades are designed to minimize friction and heat buildup during cutting. This is crucial when working with hard materials that can generate a significant amount of heat, as excessive heat can lead to blade dulling, warping, or even material damage. With PCD saw blades, you can cut with confidence, knowing that the blade will stay cool and maintain its cutting performance even during prolonged use.

Versatility: PCD saw blades are suitable for a wide range of cutting applications. Whether you're cutting hardwood, laminate, melamine, or even non-ferrous metals like aluminum or brass, there is a PCD saw blade available to tackle the job. This versatility makes PCD saw blades a cost-effective choice, as you won't need multiple blades for different materials.

Additionally, most PCD blades can come with a variety of tooth geometries, meaning it’s easy to find the right cutting tool for your application. You can also increase or decrease the number of teeth to impact your cutting speed, smoothness and heat generation.

Clean and Smooth Cuts: One of the standout features of PCD saw blades is their ability to deliver clean and smooth cuts. The sharp PCD tips slice through hard materials with ease, leaving behind a clean and polished edge. This eliminates the need for additional sanding or finishing, saving you time and effort in the finishing stages of your projects. This is especially valuable for woodworking projects that require extensive painting as it can drastically reduce your production time.

In the next section, we'll explore the various applications of PCD saw blades and how they can enhance your cutting experience across different materials and projects.

Applications of PCD saw blades:

PCD saw blades find applications in a wide range of industries and cutting tasks. Let's take a closer look at some of the common applications where PCD saw blades excel:

PCD saw blades are a game-changer for woodworking and carpentry projects. Whether you're cutting hardwood, softwood, plywood, or composite materials, PCD saw blades will provide clean, chip-free cuts. From precision joinery to cutting intricate designs, PCD saw blades ensure that your woodworking projects are executed with the highest level of precision and finesse.

Cutting laminate and melamine can be a challenge, as these materials tend to chip and splinter easily. PCD saw blades, with their diamond-infused cutting edge, are specially designed to handle these materials with ease. Whether you're cutting laminate countertops, shelving, or cabinet doors, PCD saw blades will deliver clean, chip-free cuts, ensuring a professional-looking finish.

PCD saw blades are not limited to woodworking tasks. They are also effective at cutting non-ferrous metals like aluminum, brass, or copper. The sharp PCD tips slice through these materials without clogging or gumming up, resulting in clean and precise cuts. This makes PCD saw blades a valuable tool for metal fabricators, plumbers, and electricians working with non-ferrous metals.

Composite, or advanced materials, such as fiberglass-reinforced plastics or carbon fiber composites, require specialized cutting tools due to their unique properties. Their extensive use within the automobile and aerospace industry has lead to an increase in usage of PCD tooling. PCD saw blades are ideal for cutting composite materials, as they can handle the abrasive nature of these materials while maintaining their cutting edge. Whether you're building a boat, an aircraft, or a custom carbon fiber component, PCD saw blades will provide the clean and precise cuts you need.

High-Volume Cutting: In industries like furniture production where high-volume cutting is required, such as manufacturing environments, PCD saw blades shine. Their extended blade life and exceptional cutting performance make them the go-to choice for tasks that involve continuous cutting over long periods. With PCD saw blades, you can maintain optimal cutting performance and productivity without frequent blade changes or interruptions. Reducing downtime is essential in these operation to maximize efficiency.

Now that we've explored the various applications of PCD saw blades, let's discuss how to choose the right PCD saw blade for your specific needs.

Choosing the Right PCD Saw Blade for Your Needs

Selecting the right PCD saw blade for your cutting needs is crucial to ensure optimal performance and results. Here are some factors to consider when choosing a PCD saw blade:

Different PCD saw blades are designed for specific materials. Consider the type of material you'll be cutting most frequently and choose a blade that is specifically designed for that material. Whether it's hardwood, laminate, metal, or composite materials, selecting the appropriate blade will ensure clean, precise cuts and maximize the lifespan of the blade.

PCD saw blades come in various tooth configurations, including rip, crosscut, combination, and specialty blades. The tooth configuration determines the type of cut the blade is optimized for. For general-purpose cutting, a combination or crosscut blade is usually a good choice. However, if you have specific cutting requirements, such as cutting melamine or non-ferrous metals, there are specialized blades available for those tasks.

The diameter of the blade determines the depth of cut and the size of the material you can cut. Consider the thickness of the materials you'll be working with and ensure that the blade diameter is suitable for your needs. Keep in mind that larger blades may require more powerful saws or equipment to handle the increased cutting capacity.

The arbor size of the PCD saw blade should match the arbor size of your saw or cutting equipment. Ensure that the blade you choose has the correct arbor size to avoid compatibility issues and ensure a secure fit.

When it comes to PCD saw blades, quality matters. Invest in reputable brands that are known for their high-quality blades. While the upfront cost may be slightly higher, the long-term performance and durability of the blade will outweigh the initial investment.

By considering these factors, you can ensure that you choose a PCD saw blade that meets your specific cutting requirements and delivers exceptional performance.

In the next section, we'll explore some tips for using PCD saw blades effectively to maximize their cutting potential.

Tips for Using PCD Saw Blades Effectively

To get the most out of your PCD saw blades and achieve optimal cutting results, follow these tips:

PCD saw blades require the correct speed and feed rate to operate effectively. Consult the manufacturer's recommendations or guidelines to determine the appropriate speed and feed rate for the specific blade you're using. Operating at the correct speed and feed rate will ensure clean cuts and minimize the risk of blade dulling or excessive heat buildup.

At Leitz, we take pride in our ability to run tooling at faster speeds then the majority of manufactures. Take advantage of our 140 years of experience and reach out for free technical advice today.

PCD saw blades perform best when paired with high-quality saws or cutting equipment. Invest in a saw or equipment that is capable of delivering the power and precision required for cutting hard materials. A well-maintained and properly calibrated saw will not only enhance the performance of the PCD saw blade but also ensure your safety during cutting operations.

Let the PCD saw blade do the cutting for you. Applying excessive force or pushing the material too aggressively can lead to blade dulling or even damage. Instead, let the sharp PCD tips do the work, and allow the blade to make smooth, controlled cuts. This will prolong the life of the blade and deliver clean, precise results.

Follow proper cutting techniques to maximize the performance of the PCD saw blade. This includes ensuring a stable workpiece, maintaining a steady cutting motion, and using appropriate cutting guides or jigs when necessary. Proper technique not only improves cutting efficiency but also reduces the risk of accidents or material damage.

For one-off or rare applications, its best to consolidate your machining strategy with an experienced technician to ensure you wont leave any unintended markings on the workpiece.

Regularly clean and inspect your PCD saw blade to ensure optimal cutting performance. Remove any debris or buildup that may accumulate on the blade, as this can affect its cutting efficiency and sharpness due to the material acting as a barrier between the blade and the workpiece. Inspect the blade for any signs of damage or wear, such as missing or chipped PCD tips. Replace or repair the blade as needed to maintain its cutting performance.