⚠️ Please note: this is FAKE NEWS, designed for educational purposes only.
Inadequate Guarding, No Clamping and Outdated Machinery Lead to Severe Permanent Injury
Are you still cutting aluminium like it’s the 1990s? Outdated drop saws once set the standard, but today they are a liability. With exposed blades, no guarding, and minimal clamping, they put operators at constant and unnecessary risk. Machinery without safety features has been common in workshops of the past, but most modern production workshops are prioritising safety and efficiency.
A 32-year-old aluminium fabricator has been left with life-changing injuries after his hand was partially severed while operating a drop saw at a Brisbane workshop. The incident is now under investigation by WorkSafe Queensland.
The worker, who was under pressure to meet production deadlines, operated the drop saw which did not have clamping features for the aluminium profile. Midway through the cut, the piece shifted and caught on the exposed blade. A small offcut hit and damaged the backfence and bent the blade. The operator’s hand was being used to steady the aluminium profile and was then quickly pulled into the blade.
Emergency surgery was required, and doctors say the worker may never regain full function of his left hand.
The business now faces workers’ compensation claims, reputational damage, and loss of productivity. All these are the consequences of using outdated equipment in the workplace, without safety features such as clamping and guarding.
The Hidden Danger Lurking in Workshops
This fictional incident highlights the risks associated with relying on old-style drop saws for your aluminium production. Exposed blades, lack of clamping, inadequate guarding, and manual handling combine to create dangerous conditions. Common outcomes include:
- Aluminium profile offcuts thrown into the machine, towards the operator, or across the workshop
- Severe hand and finger injuries from exposed blades
- Damage to equipment or people from uncontrolled movement of profiles
Even highly skilled, operators are vulnerable when fatigue sets in, shortcuts are taken deadlines, or operators are distracted momentarily. With drop saws, a single lapse in focus can cause permanent injuries and long-term business disruption and loss.
By failing to upgrade these machines, businesses expose themselves to avoidable risks.
Drop Saws: A High-Risk Relic
Once the backbone of aluminium workshops, drop saws are increasingly viewed as a liability. Many models lack adequate guarding, rely on the operator’s hands being dangerously close to the blade, and provide no clamping to secure the workpiece.
AMS does supply clamp kits for drop saws, which reduce some of these risks. However, the reality is clear: in today’s manufacturing environment, best practice and industry standard is Upcut Saw technology.
The Safer Solution: Upcut Technology by AMS
Modern upcut saws have been engineered with safety at their core, removing reliance on operator vigilance and building protection directly into the machine.
Our Yilmaz ACK420 Upcut Saw offers:
- Fully enclosed cutting chamber – blade is never exposed
- Advanced pneumatic clamping – secures both profiles and offcuts
- Semi-automatic cutting cycle – consistent precision, even for new staff
- Easy two-handed button operation – ensures hands always stay clear of the cutting zone
- Long service life – 10 to 20 years of reliability, costing just $3 per day over a decade
These features do more than protect workers. They also reduce rework, minimise waste, cut down on downtime and improve overall productivity. Many benefits that directly impact your bottom line.
Protect Your People, Protect Your Business
Investing in Upcut Technology protects both your team and your profitability. Contact AMS today about an Upcut Saw so you can:
- Prevent injuries and claims
- Reduce downtime and repair costs
- Comply with WHS requirements
- Deliver consistent quality
- Build a stronger safety culture and staff confidence
Drop saws are a liability and cutting like it’s still the 90’s is no longer acceptable. The upcut technology is the standard today, and the only way forward if you want to protect your team and your business.
⚠️ Please note:
This article presents a fictional scenario intended to raise awareness of the real dangers present in many aluminium fabrication environments. As suppliers to the industry, we hear from business owners and operators who have experienced serious injuries caused by outdated saws, inadequate guarding and unsafe machinery practices.
Complacency is a serious risk to workshop safety. If your team is still relying on legacy equipment, now is the time to review your setup, prioritise operator protection and invest in compliant machinery.