How To Cut Metal With A Bandsaw: No-Nonsense Guide
1 Jun 2025
When it comes to cutting metal, a bandsaw is a top tool that delivers clean, accurate results – without the sparks, noise or hassle of a grinder. Whether you’re in the workshop or on-site, a metal cutting bandsaw can make the job quicker and neater.
And if you’re wondering, “Can you use a bandsaw to cut metal?” – yes, you absolutely can. You just need the right blade, right speed and a bit of know-how.
This guide gives you the no-faff breakdown of how to use a bandsaw to cut metal safely and efficiently. If halfway through you think, “forget this,” – don’t worry. We’ll cut it for you – for free.
1
What is a bandsaw?
A bandsaw is a power tool that cuts using a looped blade stretched over two wheels. The blade runs in one direction, giving you a smooth, controlled cut – ideal for box section, bar, angle iron and more.
There are a few types of bandsaws for cutting metal:
- Benchtop bandsaws – great for garages and DIY workshops.
- Cordless/portable metal bandsaws – good for jobs on-site.
- Floor-standing models – heavier duty tools for regular metal cutting.
These aren’t your standard woodshop saws – bandsaws for cutting steel are slower, stronger and fitted with blades that can handle the heat. Some DIYers try to convert a wood bandsaw to cut metal, but between the speed difference and blade wear, it’s rarely worth the effort.
2
What metals can you cut with a bandsaw?
A bandsaw for metal work can handle loads of materials – as long as they’re thick enough. Always choose a blade where at least three teeth are in contact with the metal at the same time. This helps give a smoother, more stable cut without the risk of snagging.
It’s perfect for:
Not ideal for:
- Thin sheet metal
- Corrugated or perforated steel
Cutting metal with a bandsaw works best for solid profiles like box section, flat bar or angle. If you’re working with thin sheet, it’s better to use a guillotine or take advantage of our free cutting service.
3
Choosing the right blade
The blade makes or breaks your cut. For cutting metal, always use a bandsaw metal cutting blade – not one meant for timber. Blades for metal are built stronger and cut cleaner.
Here’s a brief overview.
- Blade width:
- Wider blades = straighter cuts.
- Narrower blades = better for tight curves or tricky angles.
- TPI (Teeth Per Inch):
- High TPI (18–24): great for thin material and cleaner edges.
- Low TPI (10–14): ideal for thicker steel and faster cuts.
Going through stainless or carbon steel? Use bi-metal bandsaw blades for cutting steel – they’ll last longer and are less likely to let you down mid-job.
4
Bandsaw settings and prep
Before you fire up the blade, there are a few things to dial in:
- Blade speed – For cutting steel, go slow. Softer metals like aluminium can handle faster speeds.
- Blade tension – Too loose and it’ll wander. Too tight and you risk snapping it.
- Blade tracking – Check the blade is centred on the wheels and isn’t pulling off-course.
If you’re using a band saw for metal, especially for thick stock, always secure the material. Clamp it down tight or use a vice. Unsecured metal is a recipe for a rough cut – or worse, a safety hazard.
5
Step-by-step: Cutting metal with a bandsaw
Here’s the no-faff walkthrough to cutting metal on a bandsaw like a pro:
- Mark your metal – Use a scribe or marker to line up your cut.
- Inspect your blade – Is it sharp? Tensioned? The right TPI? Don’t skip this.
- Adjust the settings – Speed, blade height and mitre angle if needed.
- Clamp it down – This bit’s non-negotiable.
- Start your cut – Turn on the saw and gently feed the metal in. Let the bandsaw cutting blade do the work.
- For curves – Use relief cuts to stop the blade binding.
- For portable saws – Line up the cut, lower slowly and guide through with steady pressure.
If you notice sticking or hear a screech, pause and apply a bit of wax or cutting fluid to the teeth. This is common when bandsaw blades for cutting steel are under load for long cuts.
Safety tips
Even the best bandsaw for metal won’t save you from a dodgy setup. So here’s what to keep in mind:
- PPE is a must – Goggles, gloves, ear protection.
- Keep hands away from the blade – Use guides if needed.
- Don’t force it – If the blade’s struggling, stop and re-check.
- Keep it tidy – Cluttered workspaces lead to slips and errors.
Whether you’re using a floor-standing saw or a portable metal bandsaw, these basics apply. Stay sharp, stay safe.
Do you really need to cut it yourself?
We get it – sometimes cutting it yourself feels quicker. But unless you’ve got a bandsaw for cutting steel sitting around (and know how to use it properly), why bother?
We’ve got the gear and the team to do it for you. And better yet – it’s free.
At The Metal Store, we offer a free metal cutting service with unlimited straight cuts per length or sheet. Whether it’s mild steel, aluminium, stainless or brass, we’ll cut it to size – clean and ready to go.
Need something more advanced? We also provide laser and profile cutting for more detailed jobs. Simply speak to our team or send through your enquiry and we’ll let you know if we can help.
Get your metal cut to size, delivered fast and done right – no sparks, no faff.
