MetLab/ Experimental

Precision Cutting for Advanced Materials Research and Analysis

Our specialized MetLab equipment is designed to meet the most demanding requirements of materials researchers, quality control specialists, and experimental metallurgists. Whether you’re preparing samples or conducting failure analysis on advanced alloys, our solutions ensure that your starting point is nothing short of perfection.

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Key Benefits

From the nanoscale precision of our 2-Axis Metlab Saw systems to the adaptable power of our LabMaster, Everett offers a spectrum of MetLab and experimental cutting solutions. 

Cutting Solutions

Advanced Accuracy

Customizable & Cool

cooling systems prevent thermal alterations during cutting, maintaining the integrity of even the most sensitive materials.

Cutting Solutions for Advanced Materials Research

Features

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Find the Perfect Solution

2-Axis Precision Cutting Systems

Designed for the most demanding metallographic applications, this saw sets new standards in laboratory-grade cutting precision:

Control Voltage

13.3HP

(10kW)

20HP

(15kW)

Wheel Diameter

16”

350mm

2"

Min

LabMaster

The LabMaster is engineered for flexibility in experimental settings, catering to a wide range of materials and research applications:

Control Voltage

24 VDC

(37.5kW)

20HP

(15kW)

Main Fuse Size

15 A

Max

1"

Min

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Forging the Future of Materials Analysis

At Everett, we’re not just keeping pace with materials science—we’re driving it forward. Our MetLab and experimental cutting solutions are designed to unlock the secrets hidden within every material, empowering researchers and quality control specialists to push the boundaries of what’s possible.

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LabMaster

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The LabMaster is engineered for flexibility in experimental settings, catering to a wide range of materials and research applications:

Control Voltage

24 VDC

(15kW)

20HP

(15kW)

Main Fuse Size

15 A

max

1/4”

Min

Small Wonder, Big Impact

This nimble machine packs advanced cutting technology into a workshop-friendly footprint. Its rapid-response system minimizes setup time, keeping your projects on schedule. The fine-tuned abrasive wheel delivers clean, precise cuts, making it ideal for detailed work and specialized applications. From prototype development to small-scale production, the 10″ SaferCut adapts to your evolving needs. Embrace the power of precision in a package that fits your space and exceeds your expectations.

Features

  • Visual real-time cutting-force feedback for operator
  • Green-Yellow-Red indicator LED flashes:
    • Green: when cut is within available power
    • Yellow: when current cut rate is nearing limits of the motor
    • Red: when cutting rate is exceeding the rated motor-current limits
  • If excessive cutting force continues, saw will automatically shut down to protect operator, wheel, work piece, and the saw itself
  • 15 gallon capacity tank is integrated with machine base
  • Integrated tank saves precious bench and floor space
  • The pump is submerged, making for quieter operation
  • The tank has baffles for swarf settling, and with the included wash hose, clean-out is a simple task
  • Dual pressure work holding clamp vise
  • Low pressure, finger-safe initial clamp pressure with door open
  • Once doors close and lock, vise pressure automatically increases to full line pressure to secure workpiece
  • Ask us about configuring a part-specific, custom SaferClamp workholding solution!

Key Features

Multi-Material Capability: LabMasters adapts to cut virtually any alloy with precision.

Modular Design: Easily swap cutting blades and, fixtures to tackle diverse experimental needs.

Compact layout Finger safe workholding Washdown hose Built in coolant tank

Network connectivity for integration with LIMS (Laboratory Information Management Systems)

Compliance with international machinery safety standards

enclosures for mist and debris containment

Specifications

Maximum Workpiece Diameter

5” (125 mm)

Minimum Workpiece Diameter

1/4” (6 mm) Standard Configuration

Minimum Workpiece Cut Length (with dual sided clamping)

1/2” (12.7mm)

Typical Inconel Cutting Speed

2 sec/square in

Wheel Spindle Power

20 hp (7.5-15kW)

Wheel Peripheral Speed (if wheels rated accordingly)

13,000 sfm (65 m/s)

Wheel Flange Diameter (US/EU)

4”/5.4” (102, 135mm)

Rapid Return Speed

> 10”/sec (254mm/sec)

Total Elect. Requirements (standard saw)

35 kVA

Voltage (transformers available for other voltages)

480 V

Typical Shipping Weight

4,000 lbs

Machine Dimensions

97”W x 120”D (2.5m x 3m)

Workholding Height

39” (1 m) above floor

Guards

Painted Steel

Standard Cutoff Wheel Range

Outside Diameter

16” (400 mm)

Width

0.130” (3.25 mm)

Bore

1” (25.4 mm)

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2-Axis Metalurgical Saw

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A 2-axis, 16”/400mm diameter wheel, 13.3HP/10kW semi-automatic,wet, abrasive cutoff saw for your metlab. The saw will allow your operator to use an HMI in combination with a joystick to perform cuts from behind an engineered enclosure while watching the cut through a protective window. The saw is designed to provide you with an asset life of at least 15 years and includes a full, new-machine, 12-month parts and labor warranty the entire saw (normal wear excluded), and a machine that complies with the latest machinery and control safety standards.
Wheel Spindle Power

13.3HP

(10kW)

20HP

(15kW)

Wheel Diameter

16”

350mm

1”

Min

Highly Productive Solution

The Everett Industrial Solutions Cutoff System is not your typical tool-room type saw. It is
designed, tooled, and programmed for production cutting. Highly trained and skilled operators
are not required and that fact will be carefully considered when we design the updated health and
safety aspects of this cutting system renewal.

Features

The recontroled saw is programmed to operate in four distinct modes:Manual Mode. Operator fixtures part on table, closes door, and starts saw motor, door locks automatically. Operator uses joystick to drive part through wheel or wheel through part at a speed based on how far the joystick is advanced from vertical. Operator shuts off wheel and when safety circuit detects the wheel has stopped spinning, door unlocks.

Operator fixtures part on table, positions part under wheel using the joystick. Operator sets cutting depth using dial in combination with digital readout. Operator sets cutting down feed speed using dial. On cycle start, wheel feeds down into part at selected speed until cutting depth is reached. Wheel retracts to home position and shuts off. When wheel stops spinning, door unlocks.
Operator fixtures part on table and sets the cut end position by adjusting the Table Reverse Prox Switch position. Operator uses joystick to lower the wheel to the correct depth to cut through the desired part feature and closes door. Operator sets cutting table feed speed using dial. On cycle start, table feeds part back into wheel at selected speed until table reverse position is reached. Table reverses direction and feeds forward to home position. Wheel shuts off. When wheel stops spinning, door unlocks.
For parts with a cross section too thick to be cut in one pass, in this automatic cycle, the total cutting depth is reached in multiple increments. Operator fixtures part on table and sets the cut start and end positions by adjusting the Table Reverse and Table Forward prox switches. Operator uses total depth dial to set desired total wheel down feed distance. Operator uses increment depth dial to set wheel down feed increment for each pass. Operator sets table feed speed using dial and closes door. On cycle start, table feeds part back into wheel at selected speed until table reverse position is reached. Table reverses direction and feeds forward to Table Forward position. Until total cutting depth is reached, wheel feeds down incremental distance and table feeds back into wheel, reverses, moves forward, etc. Once total cutting depth is reached, table travels forward to home position, wheel up to home position, and wheel shuts off. When wheel stops spinning, door unlocks.
The saw can cut anywhere in a rectangle approximately 4” wide, centered on the table, by 10” tall (above the table), by 14” deep (toward the back of the machine as shown in the red hashing.
The saw is built on an existing, 2-axis saw casting and base. Everett completely disassembled, cleaned, stripped to bare metal, and inspected the base saw. Everett guarantees the mechanical integrity of all castings and base structure of the saw that were reused. Following inspection, the original machine components were re-machined and/or replaced as required, cleaned, and all painted surfaces mechanically abraded for re-coating. Components were then powder-coated or painted with industrial enamels and readied for reassembly. Central way lubrication system was replaced with new.
The saw head and wheel spindle were disassembled, cleaned, and inspected for integrity. Bearings/bushings on the pivot axis are replaced with new. Pivot shaft was replaced with new. Motor mount pivot points and belt tension adjustment mechanism was restored to new condition. Saw down-feed cylinder was replaced with new and connection mounts repaired.
Cutting wheel spindle sent to spindle remanufacturer where it was completely disassembled, bearings and seals replaced, and bores and shaft ground-chromed- ground or remanufactured as required to restore appropriate bearing mounting tolerances. Arbor and motor pulleys were replaced with new and upgraded to a timing belt style. Wheel drive and clamp flanges remanufactured for appropriate fit and balance. New clamp nut and washer provided. Spindle assembly was run in and dynamically balanced to better than G2.5.

Original 10kW Deitz induction motor cleaned, stripped of paint, recoated, run in, and completely tested for operation, end play, amperage draw, and insulation integrity. Drive belts and drive pulleys replaced with new. Motor control system upgraded to a Siemens G120C variable frequency drive and a stand-alone “zero-speed” safety monitoring relay.

In addition to adjustable wheel speed, with dynamic braking by the VFD, the wheel is electronically stopped at the end of each cycle with the stopping energy burned off through resistors. This eliminates wheel spin down time, mechanical brake adjustments, heat generation in the electrical cabinet from a DC injection brake, and is indifferent to duty cycle. Furthermore, with the VFD, wheel speed can be varied based on material to be cut and process requirements (within safe operating speeds). Drive includes standard VFD features as well as ProfiSafe communications, Safe Torque Off (“STO”), Safe Stop One (“SS1”) and other safety- related functionality.
With CutSense, the saw control system provides your operator process feedback in real time to protect the operator, wheel, work, and saw from overly aggressive cutting. A LED indicator flashes colored and audible codes during the cutting cycle. Green for a moderate process (<80% of rated current use), yellow/magenta during moderately aggressive cutting (>80% but less than 100%) and red for very aggressive cutting (>100%). This feedback helps train the operator to use the power available for fast cutting cycles, but not so fast as to shorten the life of the saw and motor…or to shatter the wheel, damage the work, or damage the machine.
The cutting wheel down feed and the table in/out feed cylinders were replaced with new. Rod end bearings and connections were machined or replaced as required based on condition and wear. Cylinders were reinstalled, aligned, and tested for leaks and function. Saw position transducer and Y-axis position switches were replace with new.
The existing Hydac hydraulic power unit was sent to a professional hydraulic shop, completely cleaned, flushed, and returned to original OEM function i.e. its ability to build pressure, pressure relief valve operation, and proportional valve functionality tested and charted. The air/oil cooler was replaced with new. The cartridge oil filter element was replaced with new. The original in-tank suction filter was replaced with an external, serviceable version. All hoses were replaced with new. Unit was painted and reinstalled. All cables and hoses replaced with new.
Cleaned, powder-coated/painted, and recontroled the original coolant and chip recovery system tankage. Replaced pump and pump motor with new. Magnetic separator cleaned and painted. All coolant distribution hoses/piping replaced with new.
The saw system’s motors, hydraulics, operations, and programming are controlled by a new Siemens failsafe PLC with associated failsafe I/O cards installed in the original cabinet. Main motor control circuit and drive mounted in new, auxiliary cabinet. All electrical control components, starters, power supplies, relays, PLC and I/O cards, pushbuttons, potentiometers, and the joystick were replaced with new. Machine completely rewired.
The control system designed to adhere to the best functional safety practices (ISO13849) and to be EN Machinery Directive compliant. The safety systems are to be designed based on a detailed and comprehensive formal risk assessment to EN/ISO12100:2012-Safety of Machinery. The cutting area is fully protected in the interlocked machine enclosure for safety and to contain mist/smoke and debris. Safety interlocks prevent automatic operation of the saw if the guarding is not secured or opening the enclosure if the wheel is turning.

Key Features

Programmable Cut Sequences: Store and recall complex cutting patterns for consistent sample preparation across

Integrated Cooling System: Precision-controlled coolant application prevents thermal artifacts, crucial for analyzing heat-sensitive materials.

Specifications

Maximum Workpiece Diameter

5” (125 mm)

Minimum Workpiece Diameter

1/4” (6 mm) Standard Configuration

Minimum Workpiece Cut Length (with dual sided clamping)

1/2” (12.7mm)

Typical Inconel Cutting Speed

2 sec/square in

Wheel Spindle Power

20 hp (7.5-15kW)

Wheel Peripheral Speed (if wheels rated accordingly)

13,000 sfm (65 m/s)

Wheel Flange Diameter (US/EU)

4”/5.4” (102, 135mm)

Rapid Return Speed

> 10”/sec (254mm/sec)

Total Elect. Requirements (standard saw)

35 kVA

Voltage (transformers available for other voltages)

480 V

Typical Shipping Weight

4,000 lbs

Machine Dimensions

97”W x 120”D (2.5m x 3m)

Workholding Height

39” (1 m) above floor

Guards

Painted Steel

Standard Cutoff Wheel Range

Outside Diameter

16” (400 mm)

Width

0.130” (3.25 mm)

Bore

1” (25.4 mm)

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