Air Shears

About Air Shears

Air shears are powerful pneumatic cutting tools designed for cutting through sheet metal, plastic, and other materials with precision and minimal effort. Powered by compressed air from a compressor, these versatile tools offer tradespeople and fabricators a faster, more efficient alternative to manual tin snips or electric shears. Air shears are particularly valued on site work and in workshops where speed and accuracy are essential, delivering clean, straight cuts without distorting the material or creating excessive burr. Their lightweight design and continuous power delivery make them ideal for extended cutting sessions without operator fatigue.

The key advantage of pneumatic shears over their manual counterparts is their ability to cut continuously through tough materials whilst maintaining consistent performance. Whether you're working with steel, aluminium, corrugated iron, or plastic sheeting, air shears maintain reliable cutting power throughout extended use. Most models feature a compact, ergonomic design that allows for excellent manoeuvrability in tight spaces, making them ideal for cutting around curves, creating intricate shapes, or trimming material in situ. The reciprocating blade action ensures distortion-free cuts that require minimal finishing work.

Tooled-Up.com stocks quality air shears from trusted brands including Sealey and Draper, offering both standard shear designs and gun-style configurations for different cutting applications. These professional-grade tools are built to withstand the demands of daily workshop and site use, delivering reliable performance when connected to a suitable air compressor system. With options for cutting mild steel up to 2.5mm thick, these pneumatic shears provide the versatility needed for metal fabrication, roofing, HVAC installation, and automotive repair work.

Jargon Buster

• CFM (Cubic Feet per Minute) – The volume of air required to operate the tool effectively. Ensuring your compressor can deliver the required CFM is essential for optimal performance. Most air shears require 4-6 CFM at working pressure.
• Operating Pressure (PSI/Bar) – The air pressure needed for the shears to function correctly, typically around 6-7 bar (90 PSI) for most air shears. Always check your compressor's output matches the tool's requirements.
• Cutting Capacity – The maximum thickness of material the shears can cut through, usually measured in millimetres for mild steel. This varies by model but typically ranges from 1.0mm to 2.5mm for mild steel, with reduced capacity for harder materials.
• Stroke Rate (SPM) – Strokes Per Minute – the speed at which the cutting blade reciprocates. Higher stroke rates generally mean faster cutting through material and improved productivity.
• Throat Depth – The distance from the cutting edge to the body of the tool, which determines how far into a sheet you can cut from the edge without repositioning.
• Burr – The rough edge or raised metal left after cutting. Quality air shears minimise burr formation, reducing the need for secondary finishing work and improving cut quality.

Who Uses Air Shears?

Air shears are essential tools for a wide range of trades and industries where precise metal cutting is required:

• Sheet Metal Workers – for fabricating ductwork, flashing, and metal roofing components with clean, precise cuts
• Roofers – cutting corrugated metal sheets, metal tiles, and flashing materials on site
• HVAC Engineers – fabricating and modifying ductwork on site and in workshop environments
• Vehicle Body Repair Technicians – cutting and trimming body panels and repair sections accurately
• Fabricators and Welders – preparing metal components and trimming welded assemblies
• Maintenance Engineers – modifying and repairing metal enclosures and equipment
• Cladding Installers – cutting metal cladding panels to size with minimal distortion
• Automotive Restorers – fabricating custom panels and repair sections for classic vehicles
• General Builders – for cutting metal roofing, guttering, and flashings during construction work
• DIY Enthusiasts – for home workshop projects involving metal fabrication and repair

How to Choose the Right Air Shears

Cutting Capacity: Determine the maximum thickness of material you'll be working with regularly. Most air shears handle mild steel from 1.0mm to 2.5mm, but if you frequently work with thicker gauges, ensure your chosen model has adequate capacity with some margin for tougher materials like stainless steel or hardened aluminium.

Air Compressor Compatibility: Check your existing compressor's specifications against the tool's requirements. Air shears typically require 90-100 PSI operating pressure and consume around 4-6 CFM. An undersized compressor will result in poor performance and frequent pressure drops during operation. For professional use, a compressor with at least a 50-litre tank and 2-3 HP motor is recommended for continuous cutting work.

Tool Design: Standard in-line shears offer excellent control for straight cuts and gentle curves, whilst gun-style shears provide a different grip angle that some users find more comfortable for certain applications. Consider which design suits your typical cutting tasks and personal preference. Gun-style models can be particularly useful for overhead work or cutting in confined spaces.

Build Quality: Professional-grade tools from established brands available at Tooled-Up, such as Sealey and Draper, offer better durability, more consistent cutting performance, and longer service life than budget alternatives. Look for robust aluminium housing, quality hardened cutting blades, and comprehensive manufacturer support with readily available spare parts.

Ergonomics and Weight: If you'll be using the shears for extended periods, weight, balance, and grip comfort become crucial factors. Lightweight aluminium construction with soft-grip handles reduces operator fatigue significantly during prolonged cutting sessions. A 360° rotating air inlet prevents airline kinking and improves manoeuvrability.

Maintenance Requirements: Consider the availability of replacement blades and spare parts. Tools with readily available consumables and straightforward blade replacement mechanisms will minimise downtime and running costs over the tool's lifetime.

Popular Accessories

To get the most from your air shears and maintain safe, efficient operation, consider these essential accessories:

• Air Compressor – an adequately sized compressor is fundamental; ensure it delivers sufficient CFM and pressure for continuous operation without constant cycling
• Air Line and Quick Couplers – quality reinforced air hose (typically 8mm or 10mm bore) and quick-release couplers with 1/4" BSP connections for convenient tool connection
• Airline Filter/Regulator/Lubricator Unit – removes moisture and contaminants whilst ensuring proper tool lubrication, extending tool life significantly
• Replacement Cutting Blades – keep spare blades on hand to maintain cutting performance and minimise downtime when blades wear
• Pneumatic Tool Oil – regular lubrication is essential for maintaining performance and longevity of all pneumatic tools
• Safety Glasses – essential PPE to protect against flying metal fragments and chips during cutting operations
• Cut-Resistant Work Gloves – protect hands from sharp edges and burrs when handling sheet metal
• Hearing Protection – pneumatic tools can generate significant noise levels requiring ear defenders or plugs
• Workbench or Cutting Table – stable work surface for supporting material during cutting operations
• Tin Snips and Aviation Snips – complementary manual tools for finishing cuts and tight areas

Safety Information

Personal Protective Equipment: Always wear appropriate safety glasses or a face shield to protect against flying metal chips and fragments. Cut-resistant gloves should be worn when handling sheet metal, and hearing protection is recommended as pneumatic tools can exceed safe noise levels during extended use. Ensure compliance with HSE guidelines for workplace PPE requirements.

Tool Inspection: Before each use, inspect the air shears for damaged components, particularly the cutting blades and air connections. Never operate tools with worn or damaged blades, as this increases the risk of kickback and material snagging. Check that all guards and safety features are in place and functioning correctly. Inspect airlines for damage, wear, or leaks before connecting.

Safe Operating Practices: Ensure your work area is well-lit and free from obstructions. Always disconnect the air supply before changing blades or performing maintenance. Keep hands and fingers clear of the cutting area, and secure workpieces properly to prevent movement during cutting. Never point air shears at yourself or others, even when disconnected. Be aware of sharp edges and burrs on freshly cut material.

Air Supply Safety: Use the correct operating pressure as specified by the manufacturer – excessive pressure can damage the tool and create safety hazards. Install an airline filter to prevent moisture and contaminants from damaging internal components. Never use oxygen or combustible gases to power pneumatic tools. Ensure airline connections are secure before use to prevent dangerous whipping if disconnected under pressure.

Maintenance: Regular lubrication with proper pneumatic tool oil is essential for safe operation. Follow the manufacturer's maintenance schedule and only use genuine replacement parts. Dispose of worn blades safely using appropriate sharps containers. Never attempt to sharpen worn blades – always replace with manufacturer-specified parts.

Frequently Asked Questions

What size air compressor do I need for air shears?
Most air shears require a compressor capable of delivering 4-6 CFM at 90 PSI continuously. A compressor with at least a 50-litre tank capacity and 2-3 HP motor is recommended for professional use. Check your specific model's requirements, as continuous operation demands exceed the tool's stated CFM to account for pressure recovery time. For occasional DIY use, a smaller compressor may suffice, but expect more frequent pauses to allow pressure recovery.

Can air shears cut stainless steel?
Yes, air shears can cut thin stainless steel, but the maximum thickness will be less than for mild steel due to stainless steel's greater hardness and work-hardening properties. Expect to cut approximately 20-30% thinner stainless compared to the tool's mild steel rating. For example, shears rated for 2.0mm mild steel typically handle around 1.2-1.5mm stainless. Ensure blades are sharp and properly maintained for best results, and use slower cutting speeds to prevent premature blade wear.

How do air shears compare to electric shears?
Air shears are generally lighter, more compact, and don't suffer from motor overheating during extended use, making them ideal for continuous operation. They're also safer in wet conditions as there's no electrical current at the tool. However, they require a compressor and airlines, reducing portability compared to cordless electric models. Air shears typically offer better power-to-weight ratios than 240v mains electric equivalents and are preferred in professional workshop environments where compressed air is readily available.

How often should I replace the blades?
Blade life depends on usage intensity and materials being cut. Professional users cutting daily may need replacement every few months, whilst occasional users might get years of service. Signs that blades need replacing include increased effort required to cut, rough or torn edges rather than clean cuts, and visible damage or wear to the cutting edges. Keep blades sharp for safety and quality results – dull blades require more force and increase the risk of material slipping.

Do I need to lubricate air shears?
Yes, regular lubrication is essential for pneumatic tools. Add 3-4 drops of pneumatic tool oil into the airline connector before each use, or install an inline lubricator to automate this process. Proper lubrication prevents premature wear, maintains cutting performance, reduces friction and heat buildup, and significantly extends tool life. Never use general-purpose oils or WD-40 as these can damage internal seals and cause performance issues. Use only oils specifically formulated for pneumatic tools.