What Is a Flying Cutoff System?

A flying cutoff system (also called a flying shear) is a cutting system used in roll forming machines that cuts the profile while the material continues

A flying cutoff system (also called a flying shear) is a cutting system used in roll forming machines that cuts the profile while the material continues moving — without stopping the line.

Unlike a traditional stop-cut system, a flying cutoff:

Synchronizes with strip speed
Moves with the material during cutting
Returns to its starting position after the cut
Allows continuous production

Flying cutoff systems are commonly used in:

High-speed roll forming lines
Structural production
Stud & track manufacturing
Automotive components
Large-volume roofing operations

They are essential when production speed and efficiency are priorities.

1. Why “Flying” Cutoff?

It is called “flying” because the cutting unit:

Accelerates to match strip speed
Travels (flies) alongside the moving material
Performs the cut while moving
Decelerates and returns to its original position

The strip never stops moving.

This dramatically improves productivity.

2. How a Flying Cutoff Works (Step-by-Step)

Step 1: Strip Measurement

An encoder measures the strip length as it moves through the machine.

Step 2: Synchronization

When the programmed length is reached, the flying shear carriage accelerates to match strip speed.

Step 3: Cutting Action

The hydraulic or servo-driven blade cuts the profile while traveling with the strip.

Step 4: Return Stroke

After cutting, the carriage decelerates and returns to its starting position.

All of this happens in seconds.

3. Flying Cutoff vs Hydraulic Stop Cut

Hydraulic Stop Cut

Machine stops
Cut is made
Machine restarts
Lower cost
Slower cycle time

Flying Cutoff

Machine never stops
Higher line speed
Greater production output
Higher cost
More complex system

For high-volume production, flying cutoff offers major advantages.

4. Production Speed Impact

With stop-cut systems:

Effective speed is reduced because of stopping time.

With flying cutoff:

Continuous movement
Higher net meters per minute
Increased hourly output

Example:

Stop-cut at 20 m/min → actual output reduced due to stopping
Flying shear at 20 m/min → continuous 20 m/min output

Over a full shift, the difference is significant.

5. Types of Flying Cutoff Systems

Flying systems can be:

Hydraulic Flying Shear

Uses hydraulic cylinders
Reliable and common
Suitable for moderate to high speeds

Servo Flying Shear

Electrically controlled
High precision
Used in advanced production lines
Ideal for tight tolerances

Servo systems offer improved synchronization.

6. When Is a Flying Cutoff Required?

Flying cutoff is recommended when:

✔ Line speed exceeds 20–25 m/min
✔ Production volume is high
✔ Profile length is short (high cut frequency)
✔ Tight length tolerance required
✔ Automotive or structural precision required

It is especially useful for stud & track systems running at high speeds.

7. Advantages of a Flying Cutoff

✔ Continuous production
✔ Increased efficiency
✔ Higher daily output
✔ Reduced motor wear from frequent stopping
✔ Improved accuracy at higher speeds
✔ Smoother strip tension control

Over time, productivity gains often justify higher investment.

8. Disadvantages

❌ Higher initial cost
❌ More complex mechanical design
❌ Requires precise calibration
❌ Higher maintenance requirements
❌ More advanced control system needed

Complexity increases slightly compared to stop-cut systems.

9. Accuracy Considerations

Flying cutoff systems typically achieve:

±0.5–1.0 mm length tolerance (when calibrated)

Accuracy depends on:

Encoder quality
Servo synchronization
Hydraulic response time
Machine rigidity

Proper tuning is critical.

10. Maintenance Considerations

Flying systems require:

✔ Regular lubrication
✔ Hydraulic pressure checks
✔ Guide rail inspection
✔ Blade condition monitoring
✔ Encoder calibration

Preventive maintenance protects precision.

11. Cost Comparison

Adding a flying cutoff can increase machine cost significantly compared to a basic stop-cut system.

However:

If production volume is high,
The productivity increase can shorten ROI period.

Cost must be evaluated against expected output.

12. Industries That Commonly Use Flying Cutoff

Light gauge framing
Automotive manufacturing
Solar mounting systems
Storage & racking
High-speed roofing production
Structural steel fabrication

High-output industries benefit most.

Final Expert Insight

A flying cutoff system is a high-efficiency cutting solution that allows roll forming machines to cut profiles without stopping the line.

It improves:

Production speed
Output capacity
Operational smoothness
Overall efficiency

However, it adds:

Cost
Mechanical complexity
Advanced control requirements

For low-volume production, a stop-cut system may be sufficient.
For high-speed, high-volume manufacturing, a flying cutoff is often the superior long-term solution.