DOUBLE HEAD MITRE SAW

Double-Head Mitre Saw – Encyclopedic Entry on a Key Machine for Aluminium and Profile Cutting

1. Definition and Basic Principle

A double-head mitre saw is an industrial precision saw consisting of two opposing saw heads. Both heads are mounted on a stable guide and can work synchronously or independently. By cutting profiles simultaneously from both sides, this type of machine is ideal for aluminium profiles, plastic profiles, and in some versions, even for wood.

2. Historical Development

The first mitre saws originated as simple hand tools for woodworking. With industrialisation, stationary machines were developed. The double-head mitre saw emerged during the rise of window and façade construction in the 1960s and 1970s. With the introduction of CNC technology in the 1980s, the machine gained enormous improvements in precision and productivity.

3. Design and Construction Features

A double-head mitre saw consists of a machine bed, two movable saw heads, pneumatic clamping devices, and electronic controls. The heads are usually adjustable and allow mitre cuts between 45° and 135°. High-quality models feature noise and chip extraction, automated positioning systems, and servo drives.

4. Mode of Operation and Functional Principle

The workpiece – usually an aluminium profile – is clamped between the two saw heads. After selecting the cutting angle via the CNC control, the heads move into position. Once started, both blades cut through the profile simultaneously or sequentially. The result: millimetre-accurate length and mitre cuts, ready for assembly.

5. Typical Areas of Application

Double-head mitre saws are indispensable in profile processing:

• Window construction: cutting of frame and sash profiles

• Door construction: precise cuts for frames and hinge profiles

• Façade construction: load-bearing and connecting elements for glass and metal façades

• Conservatories: mitre cuts for glass frame structures

• Industry: cutting of aluminium beams for mechanical and lightweight construction

6. Control Technology and CNC Integration

Modern double-head mitre saws are equipped with CNC controls. These allow input of cutting data via touchscreen or CAD/CAM file import. Programs can be stored and reused for series production. Sensors monitor cuts in real time, ensuring consistently high quality.

7. Tools and Cutting Technology

Carbide saw blades with diameters between 400 and 600 millimetres are used. The teeth are specifically ground for aluminium processing. Cooling systems or minimum quantity lubrication (MQL) reduce friction and heat, extending tool life.

8. Advantages over Other Sawing Systems

Compared to single-head mitre saws or conventional chop saws, the double-head mitre saw offers clear benefits: two cuts in a single operation, higher precision, material savings, automation for series production, and flexibility for various profiles and angles.

9. Future Perspectives and Innovations

The future lies in fully automated production. Double-head mitre saws are increasingly combined with robotics, AI, and IoT systems. Automatic loading, self-learning cut optimisation, and energy-efficient drives are becoming standard, turning these saws into smart manufacturing stations.

10. Economic Importance

For window, door, and façade manufacturers, the double-head mitre saw represents an investment with a high return on investment (ROI). Thanks to speed, precision, and reduced scrap, machines pay off quickly. With rising demands for short lead times and high quality, they are an essential key technology.