Choosing Between a Second CNC Router and a Panel Saw: How to Select the Right Equipment for Your Shop

By Aaron Hughes, Project Engineer

If your shop is growing or trying to keep up with demand, there’s a good chance you’ve considered investing in machinery to increase your capacity. But the question is what would serve you better, a second CNC router or a high-speed panel saw?

The answer isn’t always obvious. Both tools are essential in panel processing, but they serve different purposes, require different workflows, and affect labor in unique ways. Here are some tips on how to break it down.

Start with Your Workflow Goals

If you are considering investing in a new machine, your end goal is to increase production, whether that’s ending a shift with 300 more cabinet doors than before or getting a custom millwork job done in half the time.

It’s important to work backward to determine the most efficient change you can make to get you the boost in production you desire. Do you need to automate and streamline your entire production process? Would simply doing more straight cuts per hour get you there?

A second CNC router offers more flexibility and automation, including shaping, drilling, machining, and cutting. However, it’s a more costly solution, and if it will be highly relied on for cutting, it won’t be nearly as efficient as a panel saw.

If you’re looking to increase throughput with minimal labor and your bottleneck involves more than panel cutting, a CNC machine will give you more return on investment.

Space and Operator Requirements

Panel saws generally have a smaller overall footprint and are simpler to operate than CNC routers. For example, the HOMAG SAWTEQ S-200’s intelliGuide feature makes it easy for an operator to know exactly where and how to place a panel for the next cut. That can be a win for smaller shops or teams with less experienced operators.

CNC machining centers typically need more floor space, more dust collection, and take more time to complete simple cutting processes than a panel saw.

If space is tight and productivity is a driving factor, a panel saw might bridge the gap—offering compact precision with high output.

The Right Tool for the Right Job

If you already have a second nested CNC machine and are looking for the next level of output, the panel saw discussion becomes much more intriguing. For most manufacturers running two nested routers at full capacity, such as the CENTATEQ N-300 PRO, there are many parts being produced that do not require secondary machining; that is, once the part is cut to size, no additional drilling or routing is needed. 

In these cases, adding a panel saw to your manufacturing process can exponentially increase your output by moving the simple rectangles and squares off the CNCs and onto a highly efficient cutting machine. This frees capacity on the CNC machines, allowing them to do what they do best: process complex parts with multiple machining operations. Your growth potential is substantially increased compared to having three CNCs all doing their own cutting.

Budget and Long-Term Growth

Investment and growth potential are always important considerations. Panel saws usually come with a lower up-front cost, faster installation time, and higher output for blanking out parts. CNC routers, while more expensive, open the door to more automation options, more complex machining capabilities, and potential labor savings.

If you’re planning for growth—or taking on more complex, high-mix work—investing in another CNC could fill the need to solve your manufacturing challenges. However, if stepping up your output to another level is a key driver, adding a panel saw for high-speed cutting operations while subsequently opening up the CNC to focus on what it does best might be the right move for your business.

Need Help Deciding? That’s Where We Come In

At Stiles, we’ve worked with shops of every size and industry to match the right automation solutions to their goals. Whether you’re considering your first CNC or looking to add another saw to balance production, our experts can help you assess your workflow and make the smart choice that sets you up for success now and into the future.

Let’s talk about where your shop is going and how we can help you get there. Contact us today to get started or check out our CNC routing machines and panel cutting solutions to learn more.