How to Cut Metal

How to cut metal with power tools

If you just want guidance on how to cut through metal as quickly and easily as possible, power tools are the obvious answer, especially when you’re working with thicker or tougher metals. There are lots of different options, so here are some of the main ways you can use power tools to cut metal at home.

How to cut metal with a magnetic (mag) drill

If you need to cut through thicker metal (like iron or steel) and make drill holes or precise cuts, a mag drill is what you need. The magnetic base keeps the drill steady by holding it firmly to the metal’s surface, giving you rock-solid stability that allows you to make clean, precise cuts and drill holes.

How to cut metal using a mag drill:

• Make sure the metal is clean, and free from rust or debris where the magnetic base will attach. Mark your cut line.

• Choose the right drill bit.

• Place the drill onto the metal and activate the magnetic base to secure it.

• Adjust the depth setting on the drill to match the thickness of the metal you’re cutting.

• Start the drill and apply steady pressure. Let the drill do the work, without forcing it, so that you don’t damage the drill or the metal.

• Drilling metal creates heat, so use cutting oil or lubricant to keep the bit cool and extend its life.

How to cut metal with a jigsaw

A jigsaw is perfect for cutting awkward shapes or thinner metals. Make sure you use a fine-toothed blade intended for metal. Don’t forget your PPE, safety glasses or goggles, ear protection and a dust mask.

How to cut metal using a jigsaw:

• Mark your cut line clearly on the metal.

• Fit the jigsaw with a metal-cutting blade and lubricate it with cutting oil to reduce friction.

• Clamp the metal down, especially if it’s a lightweight metal like aluminium.

• Move the saw slowly along the cut line to avoid overheating and snagging.

How to cut metal with an angle grinder

Angle grinders make fast work of cutting steel, aluminium and cast iron. They’re a DIY favourite because they’re versatile, fast and pretty easy to handle. But they can also be dangerous. Always wear work gloves, boots, safety goggles, a hard hat, dust mask and face shield, and make sure you follow your angle grinder’s safety instructions.

How to cut metal using an angle grinder:

• Mark your cut line clearly on the metal.

• Choose the right disc and line it up with your marked line. 

• Clamp down the metal so it doesn’t move.

• Start slowly, letting the grinder’s speed do the work for you.

• Don’t push too hard; it’ll heat up the metal and ruin the disc.

How to cut metal with a reciprocating saw

A reciprocating saw (sometimes called a sabre saw) can cut through metal pipes, rods and even metal sheets. It’s a powerful tool that gets the job done fast.

How to cut metal using a reciprocating saw:

• Mark your cut line.

• Put on goggles and ear defenders.

• Make sure you use a metal-cutting blade, and choose the right one for the thickness and type you’re working with.

• Clamp the metal securely.

• Use a slow, controlled cutting motion.

How to cut metal with a bandsaw

If you’ve been wondering how to cut metal into curves or intricate shapes, and you’re working with thicker pieces of metal, a bandsaw can work well, as long as you use a metal-cutting blade. A bandsaw is slower than an angle grinder, but it gives you more control. There are two types of bandsaw: static electric bandsaws (like those you’d use in a workshop) and portable cordless bandsaws.

How to cut metal with an electric bandsaw:

• Mark your cut line.

• Put on protective gear: eye protection, work gloves

• Use a fine-tooth metal blade.

• Set the right speed and tension for your bandsaw blade (you’ll need a slower setting for cutting metal than you’d use for wood).

• Mark out your cut line on the metal and steadily guide the metal through the blade, cutting along your marked line.

How to cut metal with a cordless bandsaw:

• Mark your cut line.

• Wear protective gear.

• Fit a metal-cutting blade.

• Position the bandsaw against the metal, making sure the blade is lined up with the cut line.

• Start the saw and slowly move it forward along the cut line.

How to cut metal with a plasma cutter

If you’re working with sheet metal and want clean, quick cuts without too much hard work, a plasma cutter is your best bet.

It’s more of an investment than some of the other tools on this list, but it makes fast work of cutting through thick metals, thanks to its use of electrically conductive gas.  

How to cut metal using a plasma cutter:

• Mark your cut line.

• Make sure your workspace is well ventilated, as plasma cutters create a lot of fumes.

• Wear suitable PPE, including a welding mask.

• Move the torch steadily across the metal, following your cut line.

• Don’t rush, let the plasma cutter slowly cut through the metal.

How to cut metal with a hole saw

A hole saw is a handy, affordable attachment for your drill that makes it easy to cut round holes in sheet metal. Whether you're running pipes through metal or need an opening for fittings, a hole saw will help you get the job done cleanly and quickly.

It’s perfect for jobs like installing vents, cutting holes for pipework or creating access points for wiring in metal panels.

How to use it:

• Attach the arbor and hole saw to your drill.

• Mark the centre of where you need the hole.

• Start drilling slowly to let the arbor/pilot drill start to bite.

• As the pilot drill cuts into the surface, keep the hole saw level and continue drilling slowly, allowing the hole saw teeth to gradually engage with the metal.

• Apply steady pressure, letting the hole saw cut without forcing it.

• Once the hole is cut, smooth the edges with a file to remove any sharp burrs.

How to cut metal with a nibbler

A nibbler is perfect for cutting sheet metal without warping it. It ‘nibbles’ away at the metal, cutting along your marked line without bending or distorting the material. 

How to cut metal using a manual nibbler:

• Line up the nibbler at the edge of your cutting line.

• Squeeze the handles to cut, working your way through the metal.

• Manual nibblers are slower than powered nibblers, but can give a cleaner cut on thin sheets.

How to cut metal by hand

Not every job needs a power tool. Hand tools come into their own for smaller cuts where every millimetre counts. Safety is still important, though. Even if you’re not using power tools, make sure you protect your eyes, face and hands from sharp blades and flying shards of metal.

How to cut metal with a hacksaw

When it comes to how to cut metal at home, the hacksaw is often all you need. Hacksaws are cheap, simple and effective for smaller cuts or thin metals. And they can cut through pipes quickly and easily.

How to cut metal using a hacksaw:

• Choose the right blade and check it’s securely attached (the teeth should face in the direction you’re going to apply pressure.)

• Secure the metal you’re working on in a vice or with clamps.

• Take it slow and steady, going too fast can make the blade overheat or cause jagged cuts.

How to cut metal with bolt cutters

If you need to cut through thicker rods or bolts (but not sheet metal) bolt cutters are ideal. They’re tough pieces of kit, so make sure you have a solid footing and good posture when you use them. 

How to cut metal using bolt cutters:

• Line up the bolt or rod between the blades.

• Apply steady pressure to the handles and let the cutters do the work.

• Don’t try to use bolt cutters on sheet metal, as it could damage the blade. 

How to cut metal with tin snips

Tin snips are basically scissors for cutting metal. They work well for cutting metals up to around 2mm thick. They give you a clean cut, but you need to be gentle, as thin metal can bend easily as you work with it.

How to cut metal using tin snips:

• Secure your metal and mark your cut.

• Slowly guide the tin snips through the metal, making sure to keep the cut straight.

• Use a file or sandpaper to smooth out any rough edges after cutting. 

How to cut metal with a pipe cutter

As its name suggests, a pipe cutter is specifically designed to cut through metal pipes (and can also be used to cut plastic pipe). It’s a handy tool for making clean, precise cuts, particularly for plumbing jobs where you need to cut copper or cut steel pipes. It’s quick, precise, and leaves a smooth finish.

How to cut metal using a manual pipe cutter:

• Clamp the pipe cutter around the pipe and tighten the knob.

• Rotate the cutter around the pipe, tightening as you go until the pipe is cut cleanly.

How to cut metal using an automatic pipe cutter:

• Place the cutter around the pipe so the blade is aligned with your cut line.

• Rotate the cutter around the pipe. The cutter will apply pressure with each turn until the pipe is cut cleanly.

Different metals call for different tools and techniques. Here’s a quick guide to how to work with different types and thicknesses of metal to help you make sure you get the right results.

How to cut through tough metal

If you’re curious about how to cut through metal that’s at the tougher end of the scale, like stainless steel or cast iron, you won’t be surprised to hear that you’re going to need tougher tools. An angle grinder with a diamond or metal-cutting disc will give you the power and precision you need. A plasma cutter is also ideal for this type of task.

When you’re working with tough metal, take your time. Rushing can make the metal overheat (and the blade wear down faster). It also increases the risk of slips and accidents.

How to cut thick sheet metal

Once you’re confident on how to cut sheet metal properly, you’ll save yourself loads of time and effort. The thicker the sheet metal, the more power you’ll need. If you’re looking to find out how to cut metal at home, an angle grinder with a metal-cutting blade or a plasma cutter are both solid choices. In industrial settings, you might have access to water jet machines or laser cutters. 

Whichever tool you go for, before you get started, you’ll need to:

1. Measure and mark where you want to cut

2. Clamp your metal sheet to a workbench or solid surface so it doesn’t move while cutting.

3. Put on your safety gear: gloves, safety glasses, dust mask, hearing protection and steel toe cap boots. 

And then:

Using an angle grinder:

• With a metal cutting disc, start slowly and let the blade lead the way. Keep the pressure steady, don’t push too hard. Be prepared for sparks to fly.  

Using a plasma cutter:

• Connect the plasma cutter and adjust the settings according to the thickness of the metal you’re working with.

• Position the plasma cutter’s torch at the start of your marked line. Engage the torch and move it steadily along the cutting line, letting the plasma arc melt through the metal.

How to cut thin metal

If you’re cutting thin aluminium and copper sheets you need a more gentle approach. Tin snips, aviation snips or a fine-toothed jigsaw blade can help you make clean, accurate cuts without tearing the metal.

Thin metals warp easily, so make sure you support them properly, and use only light pressure when you cut.

If you're working with long sheets of thin metal, it helps to lay them flat on a table or bench and use clamps to keep them steady while cutting.

How to cut corrugated metal

Learning how to cut corrugated metal the right way means you won’t end up with bent or jagged edges. The key is to pick the right tool and follow the natural lines of the corrugation as closely as possible.

Metal cutters include metal shears or nibblers, which will give you the quickest results. You can also use tin snips.

Before you begin cutting corrugated metal, put on PPE: freshly cut metal can be very sharp, so make sure you’re protected. Start cutting at the edge and work along the valleys of the corrugation for the cleanest cuts. For long pieces, take your time and adjust your tool regularly to follow the lines smoothly.

How to cut metal wire

When it comes to cutting wire, the thickness makes all the difference. For thin wire, regular wire cutters or snips will work perfectly. They give you a clean cut without fraying the ends, and they're easy to handle. Just lineup the wire with the blades, squeeze and you're done.

For thicker-gauge wire you’ll need something stronger, like bolt cutters. Bolt cutters are designed for tougher materials and will give you a cleaner cut with less effort. Make sure to position the wire close to the hinge of the cutters to maximise cutting power and avoid bending or damaging the wire.

Whatever tool you choose, take your time and focus on making precise cuts to avoid jagged or uneven edges.

How to cut a metal pole

Hacksaws are your go-to for thinner poles, but for thick steel or iron pipes you’ll need something more powerful, like a pipe cutter or reciprocating saw. 

Always secure your pipe or pole firmly in a vice before you cut it. If your pipe is moving, your cut will be uneven, and you might hurt yourself. If you’re using power tools, securing your pole or pipe properly is even more important.

Whichever method you use, always use work gloves, eye protection and a dust mask.