Questions from our customers about diamond wire saws, diamond wire, and cutting options
1) For whom is a diamond wire saw the right investment?
A diamond wire saw is particularly worthwhile if you regularly need to cut samples for quality control, research and development, or material analysis, and require extremely narrow kerfs, negligible heat input, clean cut surfaces, and clean interface surfaces.
2) What are the main advantages of cutting with diamond wire?
When cutting with diamond wire, kerf widths as narrow as 0.05 mm can be achieved. Very low cutting forces during the cut, so the required clamping forces are minimal. No edge chipping, minimal heat input (no microstructural changes). Interfaces do not smear during cutting, allowing for clean analyses afterward. High cutting depths of up to 370 mm are possible; both dry and wet cuts are possible, with good surface quality and low roughness.
3) Which diamond wire saw meets my requirements?
In practice, the selection of the appropriate diamond wire saw is based first on the maximum workpiece/cut size:
Quick decision based on workpiece size, cut length/height
TWO‑WAY:
DWS.100: up to 90 × 90 mm
DWS.175: up to 175 × 175 mm
DWS.250: up to 250 × 250 mm
ONE‑WAY :
DWS.250E (continuous loop): up to 250 × 250 mm
DWS.375E (continuous loop): up to 350 × 375 mm
The minimum kerf width must then be observed (diamond wire diameter).
TWO‑WAY:
DWS.100: from 0.05 to 0.35 mm
DWS.175: from 0.15 to 0.50 mm
DWS.250: from 0.20 – 0.50 mm
ONE‑WAY:
DWS.250E (continuous loop): from 0.30 – 0.80
DWS.375E (continuous loop): from 0.30 – 0.80
Important selection guide:
The model is decisive for the workpiece size. The cutting quality depends on the diamond wire, as well as the clamping method and the respective required parameters.
4) What is the difference between TWO-WAY and ONE-WAY diamond wires?
TWO-WAY refers to spooled wire, while ONE-WAY refers to diamond wire in a continuous loop.
There are two fundamental cutting processes:
TWO-WAY cutting process ONE-WAY cutting process Practical considerations:
- Spool wire / back-and-forth movement
- Uses spool wire (typically 20–30 m wire length)
- Enables very thin cuts (from approx. 0.05 mm)
- Continuous wire loop with a single cutting direction
- Uses wire loops (typically 2–3 m loop length)
- Allows for higher cutting speeds (up to approx. 12 m/s)
- Produces clean cut surfaces, as cutting occurs in only one direction
- Typical cut thicknesses approx. 0.30–0.80 mm
(depending on the wire diameter)
When minimal material loss is a priority, spool wire (TWO-WAY) is usually the right choice. However, if speed is more important and a slightly wider kerf is acceptable, the continuous loop is typically used.
5) How fine can cuts be made with ONE-WAY or TWO-WAY?
If you want to lose as little material as possible, diamond wire sawing is the right choice. With the Two-Way Cut using spool wire, kerfs starting at approx. 0.05 mm are possible, depending on the application. With the One-Way method, kerfs starting at 0.30 mm are possible.
6) Do you cut wet or dry?
Both are possible. You can cut wet or dry, depending on what suits your material and the desired outcome. The key advantage is that diamond wire cutting produces no significant heat input.
7) Can composite materials be cut without smearing?
Yes, it works. The diamond wire cuts composite materials cleanly without the materials smearing into each other. This keeps the interfaces clearly visible in the cross-section—ideal for quality assurance and analysis.
8) What about glass and ceramics—does edge chipping occur?
Edge chipping is generally avoided with diamond wire sawing—this is a key advantage of the process. Typical practical examples include cutting quartz glass, glass, and ceramics.
9) How important is clamping during the cutting process?
Clamping is a decisive factor. The cutting result always depends on the interaction between the machine, the diamond wire, the workpiece, and the clamping setup. With the right clamping solution, you achieve clean cuts and save on rework. To this end, we have developed a comprehensive range that covers 99% of clamping tasks.
10) Is operating diamond wire saws in everyday laboratory work complicated?
No. Our saws are designed for the simplest, menu-guided operation. All work steps are visualized with images on the display, making operation particularly easy. This feature is highly valued by our customers worldwide.
