Quick Answer: How Does Sawzall Work?
A Sawzall is a reciprocating saw that cuts by rapidly pushing and pulling a straight blade back and forth, thousands of times per minute. The tool converts the steady rotational motion of an electric motor into a fast reciprocating (back-and-forth) movement through an internal crank or scotch-yoke mechanism. This simple principle makes the reciprocating saw one of the most versatile…
Pros
- 1-1/8-inch stroke length supports fast cutting speeds
- Keyless lever-action clamp allows quick blade swaps
- Brushless motor provides heavy-duty cutting power
- Includes XR POWERPACK battery and charger
- Manufacturer rates it for up to 102 cuts per charge
Cons
- Relatively heavy kit package at 15.55 pounds
Pros
- Cordless design with high-power output for tough cutting applications
- Fast cutting specs with variable speed and a long stroke length
- Tool-free blade changes help speed up work on the jobsite
- LED light improves visibility in dim work areas
Cons
- Tool only, so the battery and charger are not included
- Best suited to users already invested in the DEWALT FLEXVOLT battery platform
- No accessory bundle or storage case is listed in the manufacturer listing
Overview & Design: The DEWALT FLEXVOLT 60V MAX Reciprocating Saw DCS389B is a cordless, tool only saw designed for cutting and demolition work. It combines a compact jobsite-friendly layout with a rubber overmold grip for added comfort and control.
Performance & Key Features: With up to 19% more power than the DCS388, 0 to 3000 spm, and a 1-1/8-inch stroke length, this saw is built for fast cutting performance. The keyless lever-action blade clamp makes blade changes easier, while the variable-speed trigger and pivoting shoe help users adapt to different materials and cutting angles.
Drawbacks & Considerations: This is a tool only version, so the battery and charger are not included. Buyers should also note that the FLEXVOLT platform is most practical for those who already own compatible DEWALT batteries or plan to invest in the system.
Verdict: The DCS389B is a strong fit for contractors, remodelers, and serious DIY users who want high cutting power without a cord. It offers a well-rounded mix of speed, control, and convenience, especially for users who need a cordless reciprocating saw for demanding work.
Pros
- Fast, tool-friendly blade changes with the lever-actuated clamp
- LED work light adds visibility during cutting
- Durability-focused battery connection helps support long-term use
- Bare tool only format can be a cost-efficient choice for existing M18 users
Cons
- Battery and charger are not included
- No detailed performance specs such as stroke length, speed, or runtime are provided in the manufacturer listing
- Best suited for users already on the Milwaukee M18 platform
Overview & Design: The Milwaukee M18 FUEL Sawzall Brushless Cordless Reciprocating Saw is a bare-tool option built for users who want a cordless cutting tool without bundled power accessories. Its brushless design and reinforced battery connection suggest a focus on durability and long-term jobsite use.
Performance & Key Features: The wear-resistant, lever-actuated blade clamp is a practical feature for faster blade changes, while the built-in LED light helps improve visibility at the cut line. As a cordless reciprocating saw, it is aimed at demolition, remodeling, and general cutting tasks where mobility matters.
Drawbacks & Considerations: This version does not include a battery or charger, so it is best for buyers already using Milwaukee M18 tools. The manufacturer listing does not list deeper performance details such as runtime, stroke rate, or included accessories, so those factors should be checked before purchase.
Verdict: This is a sensible pick for Milwaukee M18 owners who want a brushless reciprocating saw with easy blade changes and a work light. It offers solid utility in a compact product summary, but the bare-tool format means it is less convenient for first-time buyers.
Pros
- Brushless motor and 20V MAX XR platform are designed for efficient runtime.
- Compact size is well suited to tight spaces, remodeling, and stud work.
- Lightweight build helps reduce fatigue during longer cutting sessions.
- Variable speed control offers more precision for different materials.
Cons
- Tool only package does not include a battery or charger.
- Compact design is optimized for maneuverability, not maximum size or reach.
- Users needing a fully bundled kit will need to purchase compatible 20V MAX batteries separately.
Overview & Design: The DEWALT DCS367B is a 20V MAX XR cordless reciprocating saw built around a compact, lightweight form factor. At 14.5 inches long and about 5 lbs. as a tool only unit, it is designed to be easier to handle in tight spaces than larger saws.
Performance & Key Features: This model uses a brushless motor for improved runtime and delivers up to 2,900 SPM with a 1-1/8 inch stroke length. The variable speed trigger supports better control, while the keyless 4-position blade clamp and built-in LED light add convenience and visibility during cutting.
Drawbacks & Considerations: The main limitation is that this is a tool only purchase, so battery and charger are not included. Its compact format is a strength for mobility, but buyers who want a full kit or the largest cutting platform may need a different setup.
Verdict: The DCS367B is a strong fit for contractors, remodelers, and homeowners who need a portable reciprocating saw for tight access work. It offers a practical mix of runtime, control, and maneuverability without unnecessary bulk.
Pros
- Brushless motor design offers stronger performance than basic brushed models
- Fast tool-free blade changes improve jobsite efficiency
- Variable-speed trigger and 2-speed settings provide flexible control
- LED work light adds usefulness in low-light spaces
Cons
- Bare tool only, so a compatible battery and charger must be purchased separately if you do not already own them
- No detailed specs were provided for stroke length, weight, or included accessories
- Best value is mainly for users already invested in the CRAFTSMAN V20 battery platform
Overview & Design: The CRAFTSMAN V20 RP CMCS351B is a cordless reciprocating saw built as a bare tool, which makes it best suited for users already using the V20 platform. Its brushless motor and compact saw format point to a tool intended for practical cutting, demolition, and general jobsite use.
Performance & Key Features: This model offers 2-speed control with a range of 0 to 2,300 SPM on low and 0 to 3,200 SPM on high, plus a variable-speed trigger for more controlled starts and cleaner handling. The tool-free blade release is a useful real-world advantage, and the LED light adds visibility when working in darker spaces.
Drawbacks & Considerations: The biggest limitation is that this is a bare tool only, so battery and charger are not included. Buyers should also note that the manufacturer listing does not list details such as stroke length, weight, or included blades, which may matter for comparing it with other reciprocating saws.
Verdict: This saw is a solid fit for CRAFTSMAN V20 users who want a cordless reciprocating saw with brushless power, flexible speed control, and quick blade changes. It is less appealing for first-time buyers who still need to assemble the battery system from scratch.
What Is a Sawzall?
Sawzall is a brand name coined by Milwaukee for their popular line of reciprocating saws. Over decades, the term has become genericized in everyday speech, similar to how some people say “Kleenex” for any tissue. However, reciprocating saws as a tool category encompass many brands and models, each with the same fundamental operating principle.
A reciprocating saw is a handheld power tool with a straight, narrow blade that moves in a horizontal line, pushing forward and pulling backward, to cut through materials. Unlike a circular saw that rotates a round blade in a plane, or a band saw that runs a continuous loop, the reciprocating saw’s blade movement is purely linear and can access tight spaces, make curved cuts, and handle irregular surfaces that other saws cannot.
Reciprocating saws are used for demolition work (cutting through nails, pipes, and wooden studs), plumbing and electrical rough-in (cutting holes in drywall and framing), pruning branches, cutting metal and plastic pipes, and any task where you need a saw that can reach into cramped spaces. They are essential tools on construction sites and in tool collections because of their adaptability and raw cutting power.
The Internal Mechanism: Rotary to Reciprocating Motion
At the heart of a reciprocating saw is a simple mechanical challenge: how to transform the constant circular motion of an electric motor into a back-and-forth linear motion. Most reciprocating saws use one of two mechanisms to accomplish this: a crank mechanism or a scotch-yoke mechanism.
In a crank mechanism, the motor shaft is connected to a crank arm, a short rod offset from the center of rotation. As the motor spins, the crank arm traces a circle. The blade is attached to a piston or slider rod that is connected to the end of the crank arm through a connecting rod. As the crank rotates, the connecting rod pushes and pulls the piston back and forth in a linear path. The farther the crank arm is offset, the greater the blade’s stroke length (the total distance it travels forward and backward).
A scotch-yoke mechanism works similarly but with a different geometry. Instead of a connecting rod, the crank arm slides through a slot in the blade’s drive housing. This slot constrains the crank arm to move only along its length, converting the circular motion into pure linear motion. The scotch-yoke design is often more efficient and produces a more uniform blade speed throughout the stroke, but both mechanisms achieve the same goal: rapid reciprocation.
The motor speed (measured in rotations per minute, or RPM) and the crank’s offset determine the blade’s stroke frequency, how many times per second the blade moves back and forth. Most reciprocating saws operate between 2,000 and 3,000 strokes per minute when set to maximum speed, allowing the blade to make many cuts in a single second. Some models include variable speed controls that allow you to slow the blade’s motion for tougher materials or more precision.
How the Blade Action Cuts Materials
The reciprocating saw cuts by the blade’s teeth engaging and tearing through material on both the push stroke (forward) and the pull stroke (backward). Unlike a traditional handsaw, which typically cuts only on the pull stroke, the reciprocating saw’s blade is designed to cut aggressively in both directions, roughly doubling the cutting action per second. Users looking for related component recommendations can explore our marshall stanmore iii vs harman kardon onyx studio 8 breakdown.
On the push stroke, the blade’s teeth bite into the material and move forward. On the pull stroke, the same teeth pull backward through the material, continuing to cut. This dual-direction cutting is why reciprocating saws are so efficient at ripping through dense materials like wood studs, metal pipes, and composite materials quickly. The rapid blade oscillation also produces significant vibration and noise, which are inherent to the tool’s operation.
The blade’s design, tooth size, spacing, hardness, and thickness, determines what materials it can cut and how effectively. For example, a coarse wood-cutting blade has large, widely-spaced teeth that clear sawdust quickly and are ideal for fast cuts through lumber. A fine metal-cutting blade has smaller, closer-together teeth that make slower, cleaner cuts in steel or aluminum. Using the wrong blade type will result in poor cutting, rapid blade wear, and potential damage to the motor. Before finalizing equipment decisions, refer to our comprehensive dyson v8 cyclone vs bissell featherweight stick comparison.
Typical Use Cases for a Sawzall
Reciprocating saws excel in demolition because they can cut through wood, nails, drywall, and pipe without hesitation. When dismantling a wall or removing an old frame, the reciprocating saw’s ability to cut through mixed materials (wood, nails, concrete anchors) in one tool makes it indispensable. The blade can reach into tight corners and between studs where other saws cannot fit.
In plumbing and electrical work, reciprocating saws are used to cut holes through framing for rough-in installations. They can cut through copper, PVC, and galvanized pipe with appropriate blade selection. Contractors also use them for pruning thick branches and cutting roots during landscaping work. For broader ecosystem context, read through our operational guide on bissell crosswave hydrosteam vs shark stainforce.
Materials that reciprocating saws can cut include wood, drywall, metal (steel, aluminum, copper), PVC plastic, fiberglass, and cast iron, depending on the blade selected. Some heavy-duty reciprocating saws can even cut through thin concrete and masonry with diamond grit blades, though this typically requires models with higher power ratings.
Key Features and Controls
Modern reciprocating saws include several features that affect how they operate and perform. Variable speed control allows the operator to adjust the motor RPM and therefore the blade’s stroke frequency from as low as 500 to 1,000 strokes per minute up to the maximum 3,000 or more. Slower speeds provide more control and are better for delicate cuts or harder materials, while maximum speed delivers raw cutting power for demolition work.
Orbital action is an optional cutting pattern available on many reciprocating saws. In orbital mode, the blade moves not only forward and backward but also in a slight elliptical or circular motion. This additional movement lifts the blade away from the cut surface on the return stroke, reducing friction and heat buildup, and can increase cutting speed by up to 30 percent for wood cutting. Orbital action is less aggressive than pure reciprocation and can prolong blade life in repetitive cutting tasks.
The blade clamp system secures the blade to the drive mechanism. Most modern reciprocating saws use a quick-change clamp that allows tool-free blade insertion and removal. You simply pull a lever or trigger, slide the blade into the opening, and lock it in place. This design makes it fast and easy to swap blades for different materials without needing a wrench or hex key. Proper blade clamping is essential for safety and performance; a loose blade can break, bind, or cause loss of control.
Related Maintenance and Operating Guides
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Reciprocating Saw Safety Reading
A reciprocating saw blade moves quickly and can kick back, so wear eye protection and confirm the blade is secure before each cut. Broader safety information for power tools is available from American National Standards Institute (ANSI).
