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Sawing composite panels with jigsaws

This application example describes how to saw composite panels using a pendulum jigsaw and a special jigsaw blade. These enable clean, quick work that delivers a precise result, so the panels can be used as external cladding for buildings, for example.
Sawing composite panels


    This application example describes how to saw a 60-mm thick composite panel with a pendulum jigsaw. Sandwich elements are often processed for external cladding of steel buildings such as warehouses, logistics centres, production buildings, department stores, and so on.

    Sandwich material consists of two steel covering shells with shear-resistant connection to one another over a heat-insulating core made of polyurethane (PU) high-resistance foam.

    The covering shells are made of 0.6-mm thick ST 37 steel, hot-dip galvanised and coil-coated (spec. paintwork production type). They are supplied lined, flat or with trapezoidal sheeting. PUR rigid foam guarantees excellent thermal insulation. (composite panels 60 mm thick = K-value 0.32 or panels 40 mm thick = K-value 0.38.)

    At the same time, sandwich elements have a sound reduction index of Rw = 25 dBA. 

    Fitting work is required when preparing for assembly in the workshop or at the construction site. Corners must be notched, parts adjusted and radii cut.

    Previous procedure:
    Elaborate, time-consuming and exhausting sawing with a manual bow saw. 

    Cutting with angle grinders with the risk of:

    • Annealing the covering shell (unclean cut)
    • Melting the PUR rigid foam
    • Inaccurate separating cut 

    The panels can be processed quickly, cleanly and efficiently using a pendulum jigsaw and a special saw blade.


    The following tools and accessories are recommended for use in this illustrated guide:


    • Set the guide to the jigsaw blade

      • Remove the chip guard from the pendulum jigsaw
      • Set the pendulum stroke switch to position 3
      • Open the clamping screw with the hex key
      • Release the FastFix and insert the saw blade into the clamping shoe as far as it will go
      • Set the screw on the carbide guide using the hex key until the jaws are almost touching the saw blade
      • Click the chip guard back into place

      Set the guide to the jigsaw blade
    • Note:To saw composite panels you will need to:

      • Have the correct saw blade from Festool
      • Wear safety glasses, work gloves and, where applicable, body protection (to prevent injuries)
      • Work slowly – never plunge abruptly into the workpiece
      • Set speed level 4 and select a low feed speed
      • Work with dust extraction

      Requirements for sawing composite panels


      • Secure the composite panels on a table, wooden stands, or similar, with fastening clamps.
        (Alternatively: Place on the floor with approx. 15 cm thick wooden supports, e.g. square timber.)
      • Mark the panels if required
      • Connect the extractor hose to the jigsaw
      • Place the jigsaw on the composite panel
      • Switch the tool on and saw the notch/radius in the composite panels at a moderate feed rate

      Saw the notch/radius in the composite panels at a moderate feed rate
    1. Our illustrated guides and work results are documented working steps that we have performed in practice. They are individual examples and do not guarantee or promise that users will obtain the same results. The results will depend on the user's experience and skill, as well as the material being used. Illustrated guides do not replace any Festool operating manuals and/or safety instructions. Liability for ensuring that the information, instructions and applications are free from content defects and defects of title, in particular with regard to the absence of defects, correctness, freedom from third party intellectual property rights and copyrights, completeness and fitness for purpose, is excluded. Claims for damages made by the user, regardless of their legal basis, are excluded. These liability exclusions are not applicable if the damage was intentional or caused by gross negligence, or in cases of statutory liability.

      We cannot accept liability for damage resulting from defects.