02
Jun
Selecting Right Wafering Blade for your application
Cross Sectioning is the first and most important step in the sample preparation process. Getting the best resu...
SMART CUT
Fully Sintered (Metal Bond) Diamond & CBN, Wafering Blades
SMART CUT Fully Sintered (Metal Bond) diamond wafering blades are fully sintered from OD to ID of the blade. Meaning they have diamonds completely impregnated through the blade. Unlike standard diamond & cbn wafering blades with steel core and diamond section. Instead of having a steel core and small diamond bond edge (usually 1/8″/3.2mm). The diamond edge is all the way through the blade, from its Outside Diameter to Inside Diameter of the blade. You can use until the entire Outside Diameter of the blade is consumed.
DESCRIPTION
SPECIFICATIONS
FREQUENTLY ASKED QUESTIONS
INDUSTRIES USED IN
ACCESSORIES
USAGE RECOMMENDATION
DESCRIPTION
These types of blades may last as much as 3 to 4 standard blades with steel core put together. Since the entire blade is diamond and same thickness from OD to ID (with no thinner steel core to flex, warp, or loose its flatness). The fully sintered (metal bond) blades is more rigid. Providing minimum heat generation and stress to material being cut. This allows for thinner kerf thicknesses that would not be normally possible with wafering blades made with steel core, longer blade life, better cut quality and more rigidity. These are an excellent choice for sectioning large variety of ultra-hard and brittle materials, delicate samples, crystals, teeth, bones, composites, metals, and much more.
SPECIFICATIONS
Tab Contant
FREQUENTLY ASKED QUESTIONS
SMART CUT™ blades are fully sintered from the Outside Diameter (OD) to Inside Diameter (ID), meaning they have diamonds impregnated throughout the entire blade, unlike the conventional blades which have a steel core and a diamond edge. This construction allows for enhanced performance and longer blade life.
These blades offer a range of advantages:
⦁ Longer lifespan
⦁ Enhanced stability and rigidity
⦁ Consistent cutting performance
⦁ Better heat resistance
⦁ Ideal for sectioning hard and brittle materials
⦁ Reduced blade flex
⦁ Thinner kerf thickness than steel core blades
A SMART CUT™ blade may last as long as 3 to 4 standard steel core blades combined due to its fully sintered diamond composition.
They’re perfect for sectioning a wide range of materials, including fragile crystals, ultra-hard ceramics, brittle materials, teeth, bones, composites, metals, and much more
Yes! Discounts are available when purchasing in larger quantities. For example, the price per blade decreases when buying two or three at a time.
Kerf thickness refers to the width of the cut a blade makes. A thinner kerf means less material is removed, which can be crucial for precision cuts or when working with expensive materials.
Yes, the blades come in different abrasive types like Diamond (Fine or Medium) and CBN (Medium). The grit size determines the coarseness of the blade, affecting the finish and speed of the cut.
Absolutely! Since the blade is fully sintered, you can use it until the entire Outside Diameter of the blade is consumed.
CBN stands for Cubic Boron Nitride, a synthetic abrasive second only to diamond in terms of hardness. It’s particularly effective for cutting metals.
“Fully sintered” means that the blade is manufactured in a way where the diamonds are impregnated throughout the entire matrix of the blade, from the outside diameter (OD) to the inside diameter (ID), as opposed to just on the edge.
The unique construction of SMART CUT™ blades provides more rigidity, reducing friction during cutting, which, in turn, minimizes heat generation. This ensures the material being cut doesn’t get damaged due to excessive heat.
Due to their fully sintered design, the blades continuously expose new diamond grits as they wear, maintaining their sharpness. Therefore, there’s typically no need for external sharpening.
The arbor size refers to the diameter of the hole in the center of the blade. It’s essential to match the arbor size of the blade with the spindle of your cutting equipment to ensure compatibility and secure fitting.
Always follow standard safety procedures when using wafering blades. This includes wearing appropriate protective gear, such as safety glasses, gloves, and ensuring the equipment is in good working condition. Also, avoid forcing the blade through the material, which can lead to blade damage or breakage.
Store the blades in a cool, dry place away from direct sunlight. It’s recommended to keep them in their original packaging to protect them from dust and potential damage.
The choice of blade depends on the material you are cutting, the required precision, and the desired finish.
Yes, SMART CUT™ blades can cut metals, especially when using the CBN (Cubic Boron Nitride) variant, which is well-suited for cutting hard metals.
Regularly inspect the blade for wear or damage. Clean it after use to remove any debris and avoid storing it in locations where it could be exposed to corrosive elements. Proper maintenance ensures optimal performance and longevity.
Due to their thin kerf and uniform diamond distribution, SMART CUT™ blades provide precise cuts, making them ideal for delicate samples where minimal material loss is crucial.
While SMART CUT™ blades provide clean and precise cuts, achieving a mirror finish may require further polishing or finishing processes depending on the material.
The fully sintered design of SMART CUT™ blades offers enhanced rigidity, reducing the risk of warping, especially when compared to blades with steel cores.
Yes, SMART CUT™ blades are versatile and can be used on multi-material samples. However, it’s essential to consider the hardness and properties of each material to ensure the best results.
The listed sizes are the most we keep in stock. We can manufacture almost any blade specification, diameter, inside diameter, kerf thickness grit size or abrasive type
Since the blade is fully sintered with diamonds from the OD to ID, the lifespan is typically longer than standard blades. The blade can be used until its entire Outside Diameter is consumed. Regular inspection will help gauge its remaining life.
The blades are designed for durability and longevity, reducing the need for frequent replacements.
While many blades benefit from a break-in period to ensure even diamond exposure, the fully sintered design of SMART CUT™ blades typically means they’re ready to perform optimally right out of the box.
The ideal cutting speed can vary based on the material being cut and the specific blade type. These blades can be used on both low and high speed saws. Minimum recommended rpm’s is 100 and max rpm’s 12,500. Optimal rpm’s will be based on material properties, shape, and preferred cut quality and surface finish.
Thanks to the fully sintered design, as the blade wears, new diamond particles get exposed, ensuring consistent cutting performance throughout its life.
INDUSTRIES USED IN
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ACCESSORIES
Filters Sort results
Reset Apply
Image | Name | COMPATIBILITY WITH DRILL SERIES | Price | Quantity | Add to cart |
|---|---|---|---|---|---|
 | Recommended for use in Diamond Tools 150 Grit Size (mesh… | $15.39 | |||
 | Recommended for coarser grits found in segment wheels, core drills… | $15.99 | |||
 | $34.81 | ||||
| Recommended for use in Diamond Tools 150 Grit Size (mesh… | $39.47 | |||
| Recommended for coarser grits found in segment wheels, core drills… | $39.47 | |||
 | $99.81 | ||||
 | $317.41 | ||||
 | $1,745.00 |
USAGE RECOMMENDATION
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Filters Sort results
Reset Apply
Image | Item No | Outside Diameter | Kerf Thickness | Arbor Size / Inside Diameter | Abrasive Type / Grit Size | Price | Quantity | Add to cart |
|---|---|---|---|---|---|---|---|---|
 | 3030604 | 3" (76.2mm) | .006" (0.15mm) | 1/2" (12.7mm) | Diamond / Fine | $165.00 2 pcs - $160.00 ea ⋅ 3 pcs - $155.00 ea | ||
| 3030605 | 3" (76.2mm) | .006" (0.15mm) | 1/2" (12.7mm) | Diamond / Fine | $165.00 2 pcs - $160.00 ea ⋅ 3 pcs - $155.00 ea | ||
| 3030402 | 3" (76.2mm) | .004” (0.10mm) | 1/2" (12.7mm) | Diamond / Fine | $185.00 2 pcs - $160.00 ea ⋅ 3 pcs - $155.00 ea | ||
| 3030608 | 3" (76.2mm) | .006" (0.15mm) | 1/2" (12.7mm) | CBN / Medium | $185.00 2 pcs - $180.00 ea ⋅ 3 pcs - $175.00 ea | ||
| 3030408 | 3" (76.2mm) | .006" (0.15mm) | 5/8” (15.87mm) | Diamond / Fine | $185.00 2 pcs - $180.00 ea ⋅ 3 pcs - $175.00 ea | ||
| 3030405 | 4" (101.6mm) | .006" (0.15mm) | 1/2" (12.7mm) | Diamond / Medium | $185.00 2 pcs - $180.00 ea ⋅ 3 pcs - $175.00 ea | ||
| 3030406 | 4" (101.6mm) | .008” (0.20mm) | 1/2" (12.7mm) | Diamond / Medium | $185.00 2 pcs - $180.00 ea ⋅ 3 pcs - $175.00 ea | ||
| 3030407 | 4" (101.6mm) | .010” (0.25mm) | 1/2" (12.7mm) | Diamond / Medium | $185.00 2 pcs - $180.00 ea ⋅ 3 pcs - $175.00 ea | ||
| 3030404 | 4" (101.6mm) | .013" (0.33mm) | 1/2" (12.7mm) | Diamond / Fine | $185.00 2 pcs - $180.00 ea ⋅ 3 pcs - $175.00 ea |
3030604,3030605,3030402,3030608,3030408,3030405,3030406,3030407,3030404,
Advantages
- Longer Life: Fully sintered blades tend to have a longer lifespan than resin-bonded or steel core blades. This is because the diamonds are embedded throughout the entire blade matrix, not just at the edge.
- More Stable and Rigid: The uniform composition of a fully sintered blade offers better stability and rigidity than blades with a steel core. This can result in straighter cuts with fewer deviations.
- Wear Uniformity: As a fully sintered blade wears, new diamond grits are continually exposed, maintaining cutting performance over the life of the blade.
- Heat Resistance: Metal bonded blades generally possess better heat resistance compared to resin-bonded or steel core blades.
- Sectioning Hard and Brittle Materials: Fully sintered blades are often chosen for sectioning hard and brittle materials because they maintain their edge and shape over prolonged usage.
- Reduced Blade Flex: Since they're made entirely of the sintered material, these blades have less flex, which can be essential when precision and sectioning accuracy are crucial.
- Thinnest Possible Kerf thickness – that would not be possible with steel core
About Sintered (Metal Bond)
Sintered (Metal Bond) diamond tools have multiple layers of diamonds impregnated inside the metal matrix. Diamonds are furnaces sintered in a matrix made of iron, cobalt, nickel, bronze, copper, tungsten, alloys of these powders or other metals in various combinations. Metal bonded diamond tools are “impregnated” with diamonds. This means that selected diamonds are mixed and sintered with specific metal alloys to achieve the best cutting performance possible on any materials such as sapphire, advanced ceramics, optics, glass, granite, tile and etc. The metal bond surrounding the diamonds must wear away to continuously keep re-exposing the diamonds for the diamond tool to continue cutting. Sintered (metal bonded) diamond tools are recommended for machining hard materials from 45 to 75 on rockwell scale (5 to 9.5 on mohe’s scale of hardness).
No Glazing
Diamond & CBN tools with SMART CUT technology require minimum dressing, the bond renews itself.
Faster Drilling Action
Diamond & CBN tools made utilizing SMART CUT technology are much more aggressive than your conventional tools. They can cut faster, while still leaving behind a smooth finish free of material deformation.
Manufactured Using The Highest Quality Raw Materials
Only the highest quality synthetic diamonds and raw materials are used in the manufacturing process. The highest quality standards and product consistency is maintained, using sophisticated inspection and measurement equipment.
Best Performance & Value on the Market
SMART CUT Diamond Drills are the best investment you can make! Although they may cost more than Diamond Drills. They will more than pay for themselves in terms of overall performance and provide best.
Longer Life
In most cases tools manufactured utilizing SMART CUT technology, will outlast other conventional Sintered (Metal Bond) diamond & CBN drills. SMART CUT diamond & CBN tools are more sturdy than tools manufactured with conventional technologies. They are capable to retain their form and bond configuration all the way through the tools life.
More Consistent Performance
SMART CUT Diamond & CBN, Wafering Blades have hundreds of diamond layers impregnated inside the Metal Bond matrix. Unlike Many Other drill Types, they wear evenly, and are known for their consistency. You will get consistent cutting speed, and overall consistent performance, with minimum amount of dressing even on the hardest to cut materials
Its what you cant see that makes all the Difference
Its What You Cant See That Makes All The Difference
SMART CUT® technology
How SMART CUT ® Bond Works?
Step 1
Sharpest And Finest Quality Diamonds
The newly exposed diamonds don’t effect diamonds already working on the material. Unlike many other diamond bonds, diamonds in a SMART CUT ® Bond remains sharp and grow sharper with each cut, prolonging product life and consistent performance.
Step 2
Diamonds or CBN Crystals
Diamonds or CBN Crystals are activated only at the exposed layer. As Bond Matrix layer begin to wear out, diamonds in a new Bond Matrix layer are immediately activated, substituting the already used up diamond layer. The SMART CUT Diamond Hybrid Bond makes sure every diamond is in the right place and at the right time, working where you need it most.
Step 3
Advanced Formulated Open Diamond Bond Design
This advanced formulated open diamond bond design insures minimal chipping, fast cut, constant speed of cut, minimal cutting noise, and most important of all, consistent performance.
Diamond Wafering Blade
Selection Variables
Diamond Concentration :
Diamond Concentration is still a factor in determining the life and cutting speed of your Diamond Sectioning/Wafering Blade. Higher diamond concentration is recommended and usually used for cutting softer and more abrasive types of materials. However, the trade off is significantly slower cutting speed. Low diamond concentration is recommended and widely used for cutting ultra hard and brittle materials.
Low Diamond Concentration - Typically low concentration wafering blades should be for cutting ultra hard and brittle materials such as ceramics and glass. In Low Concentration Wafering Blades, diamond works by fracture process. Pressure on each diamond crystal/particle is higher which provides enough stress to chip off small flakes in the cut.
High Diamond Concentration - High concentration diamond wafering blades are recommended for cutting metals, plastics and polymers. In this application, materials cut by a plowing mechanism. In this applications diamond plough through the material, work hardened strips of materials become brittle and break off. The greater number of diamond by volume, the quicker the cutting action will be. Increasing the number of diamond s also lowers the per unit force. For metals where it is possible to induce deep deformation layers, a lower per unit force is desirable to reduce the deformation during the cut.
Diamond Particle/Grit size -
Diamond Mesh Size plays a major role in determining your cutting speed, cut quality/surface finish, level of chipping you will obtain, and material microstructure damage you will obtain. Diamond Mesh size does have considerable effect on cutting speed. Coarse Diamonds are larger than finer diamonds and will cut faster. However, the tradeoff is increase in material micro damage. If you are cutting fragile, more delicate materials then finer mesh size diamond wafering blades are recommended.
Blade Thickness :
Wafering blade thickness typically ranges from .006” to .040” (1mm). Thinner and thicker wafering blade are available, frequently from stock upon request. Kef thickness typically increases with blade diameter (in proportion to diameter of the blade). Kerf is the amount of material removed from the material/sample due to the thickness of blade passing though the material/sample. Blade thickness is important for users requiring most minimal amount of material loss during sectioning. For example if the user requires precision position of the cutting plane relative to the detail on the sample (IC circuit for example), a thinner and smaller diameter blade would be best for this application. Blades ranging from 3” to 5” (75mm to 125mm) in diameter and thickness .006” to .015” (0.2mm to 0.4mm) would be bet suited for this purpose. There are large variety of factors that will contribute to optimal blade thickness for your material/application Including your desired cutting speed, load/feed rate, material diameter, thickness, hardness, density, and shape. As well as skill & experience of the operator. Thicker wafering blades are more stiff and can whistand higher loads/feed rates. Another advantage of thicker kerf blades is they are more forgiving to operator error and abuse. Thicker kerf blade are recommended for use in environment where large number of individuals will be sharing and using same equipment. Perfect for less experienced and novice saw operators, such as in University laboratory.
Blade Outside Diameter :
Typically wafering blade diameters range form 3” (75mm) to 8” (200mm). Wafering blade diameter should be selected based on material diameter and thickness being cut. Smaller diameter wafering blades are thinner than the larger diameter blades and are more prone to bending and warping. Although large diameter blades are thicker, they are typically used for cutting larger and heavier samples at higher loads and speeds than smaller blades.
Bond Hardness :
Ability of the bond matrix to hold diamonds. As the hardness of the bond is increased, its diamond retention capabilities increase as well. However the trade off is slower cutting speed. Life of the diamond blade is usually increased with hardness of its bond matrix. Bonds are designated on their scale of hardness from Soft, Medium, and Hard. There are dozens of variations and classification schemes based on bond degree of hardness or softness. Using diamond blades with optimum bond hardness for your application is important to successful precision diamond sawing operation. Bond matrix that is too soft for the material being cut will release diamond particles faster than needed, resulting in faster wear and shorter diamond blade life. On other hand bond matrix that is too hard will result in much slower cutting speeds and require constant dressing to expose the next diamond layer. As rule of thumb, harder materials such as sapphire and alumina generally require a softer bond. Whereas softer and more brittle materials require a harder bond.
Bond Type :
Metal bonding offers long life and durability, while resin bonding creates less heat, provides better surface finish and is well suited for cutting hard, delicate or brittle materials.
Feed Rates :
Load/Feed Rate applied to wafering blades typically vary from 10-1000 grams. Generally, harder specimens are cut at higher loads and speeds (e.g. ceramics and minerals) and more brittle specimens are cut at lower loads and speeds (e.g. electronic silicon substrates). The Speeds/RPM’s you are using, shape/geometry of the specimen, and how the specimen is being clamped/hold in place will affect the load that can be used for your application.
Blade Speeds/RPM’s :
Most wafering blades are used between 50 to 6,000 RPM’s Typically harder and more denser materials such as Silicon Carbide, are cut at higher RPM’s/speeds Where more brittle materials such as silicon wafers and gallium arsenide are cutting at lower RPM’s. Low Speed saws RPM’s are typically limited from 0 to 600 RPM’s. Where high speed saws offer much large variety of cutting speeds from 0 to 6,000 RPM’s.
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We produce diamond consumables for some of the leading world OEM manufacturers. We offer Manufacturers Direct Prices
We have the largest variety of diamond & cbn wafering blades available in stock. As well as large inventory of diamond & abrasive consumables. We also custom manufacture diamond and cbn tools, consumables and machines to better fit customer specific needs. Just about any tools & consumables can be designed and manufactured per client drawing or specificrtion
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Related Products
SMART CUT® Series 3000R Resin Bond, Diamond Cut Off Blade
Resin Bond Diamond Cut off blades (Fine Size Diamond) for use on manual tile saws
SMART CUT® Series 3000R Resin Bond Diamond Cut Off Blades are Finer Diamond Grit Size, and Slightly Higher Diamond Content then the SMART CUT Series 3000 blades. They are used for cutting very thin wall tubing, more fragile material, that need best surface finish possible to achieve. Cutting speed would be slower then the 3000 series.
SMART CUT® Series 400 Wafering Blade, Resin Bond
Resin Bond Diamond Wafering Blades for use on Precision & Laboratory type Cut off Saws
SMART CUT® Series 400 are Designed for Precision, Chip Free cutting of wide variety of materials These are very thin kerf blades and are very delicate. Must be used on high precision specialized laboratory cutting saws (not tile saws, trim saws, etc) The diamond section can be easily broken if the material moves while cutting, blade is dropped, material is feed to fast into the blade, material is not fed consistently straight into the blade (shifts position) etc. Diamond Size is Medium providing faster cutting speed, while still providing surface quality unmatched by 95% of other blades.
SMART CUT 105N Diamond, Nickel Bond Wafering Blades INTERRUPTED RIM
SMART CUT™ Series 105N more freer cutting & aggressive than continuous rim nickel bond wafering blades. Best Suited for cutting larger variety of micro-electronics packages, pcb boards, plastics, composites, soft and precious metals, fish and human bones, graphite, GRP, FR4. Core steel with memory. Always snaps back to its original shape no matter how much bent.
Standard arbor size inside diameter is ½” (12.7mm) (* we can modify arbor size of any blade to anything you want same day for a small additional fee, if needed)
Nickel Bond Diamond Cut off blades Blades usually have a single layer of diamonds, held by a tough durable nickel alloy. diamond particles to protrude from the bond matrix, providing a free, faster cutting action with minimum heat generation.
SMART CUT® Series 100N Wafering Blade, Nickel Bond
NICKEL BOND, DIAMOND CONTINUOUS RIM
SMART CUT™ Series 100N will provide finer cut quality than interrupted rim nickel bond wafering blades. Best suited for cutting soft and fragile crystals, silicon wafers & substrates, fiberglass, glass fibers. made with stainless steel core Standard arbor size inside diameter is ½” (12.7mm) (* we can modify arbor size of any blade to anything you want same day for a small additional fee, if needed) Nickel Bond Diamond Cut off blades Blades usually have a single layer of diamonds, held by a tough durable nickel alloy. diamond particles to protrude from the bond matrix, providing a free, faster cutting action with minimum heat generation.Recently Viewed Products
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UKAM Industrial Superhard Tools is a U.S. High Technology, Specialty Diamond Tool & Equipment manufacturer. We specialize in producing ultra thin & high precision cutting blades and precision cutting machines diamond drills, diamond micro tools, standard & custom advanced industrial diamond tools and consumables.
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