Air Saws

Air saws – also known as pneumatic saws – are high-speed cutting tools powered by compressed air and designed for precise, controlled cutting of metal, plastic, wood, and composite materials. Commonly used in automotive bodywork, construction, fabrication, and maintenance applications, air saws are valued for their lightweight build, low vibration, and ability to perform intricate cuts in confined or awkward spaces.

An air saw is a pneumatic hand tool that uses compressed air to power a reciprocating blade for cutting through a wide range of materials. Unlike electric saws, which contain a motor, air saws rely on an external air compressor, making them lighter, more durable, and ideal for continuous use in busy workshops or industrial settings.

There are different types of air saws, including:

• Reciprocating air saws: Used for general cutting, especially in tight spots

• Body saws: Smaller, high-speed saws ideal for cutting thin sheet metal or plastics

• Jigsaw-style air saws: For more precise, shaped or curved cuts

• Select the right blade: Choose a blade that suits your material and application – fine-toothed for sheet metal, coarse for wood or plastic.
• Connect to compressor: Use a secure airline and ensure pressure is set according to the manufacturer's guidance (usually 90 PSI)
• Secure your material: Clamp or stabilise the workpiece to ensure safe, accurate cutting.
• Wear Suitable PPE: Safety glasses, gloves, and hearing protection are essential. For cutting or grinding metal, a face shield is also recommended.
• Position the tool: Hold the saw firmly with both hands and position the blade at the start of your cutting line.
• Start cutting: Press the trigger gently to begin. Let the tool do the work; don’t force it through the material. Follow your marked cut line carefully.
• Control your pace: Air saws operate at high speeds; use steady pressure and let the blade move freely. Stop periodically to prevent overheating of the blade or material.
• Finish and disconnect: Once the cut is complete, release the trigger, allow the tool to stop fully, and then disconnect the air supply.

Air saws operate by converting the energy of compressed air into a mechanical reciprocating (back-and-forth) motion. Here's a step-by-step breakdown of how it works:

1. Compressed air enters the tool through the inlet hose, typically regulated to 90 PSI (6.2 bar).

2. The air drives a small internal piston, which moves rapidly back and forth.

3. This piston motion is transferred to a mounted saw blade, creating a high-speed cutting action (often up to 10,000 strokes per minute).

4. The trigger controls the air flow and, therefore, the speed of the cut.

5. When the trigger is released, the air flow stops, and the saw blade ceases m.

Because the tool has few moving parts and no electrical components, it’s robust, low-maintenance, and suitable for harsh environments or prolonged use.

 Maintaining your air saw is key to ensuring safe operation, consistent cutting performance, and long tool life. Here’s how to care for it:

• Daily oiling: Use pneumatic air tool oil (such as ISO 22) before and after use. Simply add a few drops into the air inlet to lubricate internal parts. Alternatively, use an in-line lubricator or filter-regulator-lubricator unit to maintain clean and lubricated airflow.
• Check air lines: Ensure hoses are free from leaks, kinks, and moisture. This is also vital to ensure user safety.
• Drain compressors daily: Prevent water vapour from entering and corroding the tool and rusting the compressor tank.
• Store properly: Keep the tool in a dry place and ideally in a case when not in use.
• Check the blade: Always inspect the blade before use for signs of wear, chipping or bending. Replace worn blades to avoid damage or injury.