Oil palm frond (OPF) is a major agricultural by-product whose mechanical behaviour controls harvesting operations. This study investigates how moisture content (MC) affects the cutting force and mechanical behaviour of OPF when using a cordless electric reciprocating saw. Optimising the handling of OPF, a major oil palm by-product, is important for improving sustainability and harvesting efficiency. OPF samples were classified into four moisture categories: Fresh (75%–100%), moderately dry (50%–75%), dry (25%–50%), and very dry (0%–25%). Cutting force was measured using a load cell, while mechanical properties were assessed through three-point bending tests and porosity was determined via scanning electron microscopy. Results show that the cutting force and specific cutting force (SCF) decrease significantly as MC increases. The driest samples required the highest cutting effort, while fresher ones were easier to cut. Flexural strength and stiffness increased as moisture decreased, while porosity declined. These findings highlight the importance of moisture in tool performance and support the development of more ergonomic, energy-efficient and automated harvesting solutions.