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 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.