Cast Saw Blades
Cast Saw Blade to replace a Stryker, DeSoutter, American Orthopedic, M-Pact, or BSN cast cutter.
When to replace a cast saw blade?
As you can imagine, a patient is often concerned about a cast saw coming close to their limb. So it is important that when that blade does not cut easily into a cast for speedy removal. It is time to get a new blade. The length of like of a cast saw blade will be determined by the metal the blade is made from and also the materials it is cutting i.e. Plaster, Fiberglass, Polyester, or Bone.
How to determine what cast saw replacement blade to choose?
Often technicians will choose to replace a blade with the same blade the saw came with. However, each blade is different and costs different materials. If you were happy with how long that blade lasted. Then you may want to keep the same blade type. But you may find you get more bang for your buck by spending a little more to get a coated blade specific for the material you are cutting.
Why are there different types of cast cutter blades?
Cast saw blades are all made from stainless steel. Some of these blades are “coated” using different scientific processes to make them last longer or run cooler during the cutting process, or both. The “coatings” vary in cost based mostly on the complexity of their applications, and the performance attributes they possess.
Types of coatings are often seen on cast saws blades. In order of strength. # 1 being the strongest blade coating.
#1 Dichronite blade (coated)
#3 Titanium Nitrided blade (coated)
#4 PTFE (Teflon coated)
When to replace a cast saw blade?
As you can imagine, a patient is often concerned about a cast saw coming close to their limb. So it is important that when that blade does not cut easily into a cast for speedy removal. It is time to get a new blade. The length of like of a cast saw blade will be determined by the metal the blade is made from and also the materials it is cutting i.e. Plaster, Fiberglass, Polyester, or Bone.
How to determine what cast saw replacement blade to choose?
Often technicians will choose to replace a blade with the same blade the saw came with. However, each blade is different and costs different materials. If you were happy with how long that blade lasted. Then you may want to keep the same blade type. But you may find you get more bang for your buck by spending a little more to get a coated blade specific for the material you are cutting.
Why are there different types of cast cutter blades?
Cast saw blades are all made from stainless steel. Some of these blades are “coated” using different scientific processes to make them last longer or run cooler during the cutting process, or both. The “coatings” vary in cost based mostly on the complexity of their applications, and the performance attributes they possess.
Types of coatings are often seen on cast saws blades. In order of strength. # 1 being the strongest blade coating.
#1 Dichronite blade (coated)
Another very effective blade coating is Tungsten Disulfide, or “Dichronite”. It is dry film lubrication applied to stainless steel blades under high air pressure. The steel blade “accepts” the coating as it bonds exceedingly well, causing a very lubricious surface when the treatment is complete. Other extremely hard compounds and elements such as Boron have also been used in this manner with much success. These types of coatings afford users lower cost performance attributes such as extended blade life and cooler cutting temperatures.
#2 Ion Nitriding (coated)
Currently, the most effective process available for maximizing cast saw blade life is Ion Nitriding.
This “high-tech” process, also known as “plasma coating”, uses electron bombardment of nitrogen ions to form an incredibly strong, yet smooth surface to a base steel cutter blade. The process takes place in a vacuum vessel under a very high voltage charged environment. The effect on the blade surface is a hardness factor nearly that of diamonds; and a very smooth surface that has very little drag coefficient.
This “high-tech” process, also known as “plasma coating”, uses electron bombardment of nitrogen ions to form an incredibly strong, yet smooth surface to a base steel cutter blade. The process takes place in a vacuum vessel under a very high voltage charged environment. The effect on the blade surface is a hardness factor nearly that of diamonds; and a very smooth surface that has very little drag coefficient.
#3 Titanium Nitrided blade (coated)
Titanium nitride is a gold “ceramic” coating that is applied to a stainless steel base blade. Once applied, the blade surface becomes exponentially harder, and the drag coefficient is dramatically lessened. This results in much cooler surface temperatures during actual cutting, and longer saw tooth sharpness. Titanium coating adds a thin layer that protects the teeth, maintaining their effectiveness for a longer timeframe.
#4 PTFE (Teflon coated)
Teflon is a very lubricious, slippery coating which is applied to the stainless-steel blade. The process is much like spray painting and takes place at room temperatures. When dry, and cured, the Teflon provides a non-stick, low drag coefficient surface that slides smoothly through casting materials. The drawbacks are that Teflon tends to wear off not long after first use. So, despite the low friction surface, the material often fails to stay permanently bonded, so some degradation is seen. Despite this small downside, PTFE-coated blades remain quite popular.
#5 Stainless Steel (not coated)
#5 Stainless Steel (not coated)
Stainless Steel blades are not coated. They are, however, made of high carbon stainless alloy, which is “tempered” using a high-temperature hardening process that makes the steel much harder; therefore makes its teeth last longer during the cutting process. As the blade is used, the teeth gradually lose their sharpness over time. This results in a longer cutting time, and heat due to increased friction will be the result. A dull blade will produce so much heat that it may be felt by the patient even through the cast padding. A normal general orthopedic practice that removes 10 casts per week can expect a single stainless steel blade to last a month or two before needing to be changed.
 (64mm diameter) Circular Stainless Steel Cast Saw Replacement Blade_thumbnail.jpg)
