The Home Tools Pro

Best Saw for Cutting Metal: Chop, Band, Jigsaw or Grinder

By Md. Asrafuzzaman (MA Zaman) · Updated

The best saw for cutting metal depends on the cut:

  • Straight cuts in steel bar, tube and angle: a metal-cutting chop saw (abrasive or dry-cut) or a band saw.
  • Curves and sheet metal: a jigsaw with a bi-metal blade.
  • Pipe and bolts in place: a reciprocating saw.
  • Fast, rough cuts: an angle grinder with a cut-off wheel.

Each of these saws needs a blade made for metal, with fine teeth (high TPI), and most run slower in metal than in wood. A wood blade dulls almost at once or breaks.

Metal-cutting saws compared

SawCut typeBest forFinishWatch out for
Abrasive chop sawStraight, square or miteredSteel bar, tube, angle, rebarHot, burred edgeSparks, dust, wheel wears smaller
Dry-cut / cold sawStraight, square or miteredRepeated clean cuts in steelClean, cool, nearly burr-freeHigher cost; blade must suit the material
Band saw (metal)Straight, some curvesBar, tube, pipe; unattended cuts on horizontal modelsCleanSlow on thick stock; needs a metal-speed saw
JigsawCurves, straightSheet metal, thin tube, cut-outsFairBlade bends in thick metal
Reciprocating sawRough, any anglePipe, bolts and studs in place, demolitionRoughVibration; hard to cut straight
Angle grinder + cut-off wheelShort straight cutsBolts, rebar, sheet, tile and stoneRough, hotKickback and wheel breakage; always use the guard
Metal-cutting circular sawStraightSteel sheet, plate, studsClean, coolDedicated saw and carbide blade needed

Which saw for which metal job

JobBest choiceWhy
Cutting steel tube for a frameChop saw (dry-cut or abrasive)Square, repeatable cuts with a vise and miter
Aluminum extrusion and trimMiter or chop saw with a non-ferrous carbide bladeClean, accurate cuts; see can I cut aluminum with a chop saw
Curves in sheet steelJigsaw, bi-metal blade, 24 to 32 TPIFollows a line; clamp the sheet to stop vibration
Cutting off a rusted boltReciprocating saw or angle grinderReaches into tight spaces
Long straight cut in sheet steelMetal-cutting circular saw, or jigsaw with a guideStraighter than a grinder
Round bar and pipe in the shopHorizontal band sawClean cut, runs on its own

If you already own a band saw for wood, read can a wood bandsaw be used for metal: it can, but only at a much lower blade speed.

Choosing the right blade

  • Teeth per inch (TPI): keep at least three teeth in the material at all times. Thin sheet and tube need 24 to 32 TPI; solid bar and thick plate 14 to 18 TPI.
  • Bi-metal blades (HSS teeth on a flexible spring-steel back) last far longer than carbon steel blades in metal; they’re the standard for jigsaws, reciprocating saws and band saws.
  • Carbide-tipped blades are used on dry-cut, cold and metal-cutting circular saws; use the blade the saw maker specifies for the metal.
  • Abrasive wheels are rated for a maximum speed (rpm); never fit a wheel rated lower than the saw.

For blade choices on a jigsaw, see the best jigsaw blades for metal cutting.

Safety when cutting metal

  • Wear eye protection (a face shield for grinders and abrasive saws), gloves and hearing protection.
  • Clamp the work; never hold small pieces by hand.
  • Keep sparks away from flammables, and clear wood dust from the saw before cutting steel.
  • Freshly cut metal is hot and sharp; deburr the edge with a file.

Frequently asked questions

Can a wood circular saw cut metal?

Only with a blade made for metal and only if the saw's speed suits it. Dedicated metal-cutting circular saws run slower and collect chips; a wood saw with an abrasive wheel throws sparks and dust into a motor not built for them.

What TPI blade cuts steel?

Keep at least three teeth in the material at once. That usually means 18 to 24 TPI for thick steel and 24 to 32 TPI for thin sheet and tube.

Abrasive chop saw or cold saw?

An abrasive saw is cheap and cuts most steels but leaves heat, sparks and burrs. A cold saw or dry-cut saw costs more but gives a clean, square, cool cut and is quicker on repeated cuts.

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