How To Cut Metal With A Circular Saw: No-Faff Guide
3 Jun 2025
Think circular saws are just for timber? Think again. With the right setup, a circular saw for metal cutting can slice through aluminium, mild steel, brass and more – quickly, cleanly and without the noise or sparks you’d get from an angle grinder.
Whether you call it a metal circular saw, a power saw for metal or just your go-to tool for straight cuts, this guide gives you the lowdown on how to cut metal safely and accurately – without the faff. And if you decide you’d rather not deal with blades and clamps, we’ll do the cutting for you – free of charge.
1
What is a circular saw?
A circular saw is a handheld power tool with a rotating disc-shaped blade. Unlike chop saws or mitre saws, it’s not locked into a cutting base – giving you more freedom to make long cuts or tackle awkward pieces. It’s compact, portable and ideal for jobs where flexibility matters.
You’ll find everything from basic DIY models to heavy-duty ones with more power and features. For metalwork, look for saws with an enclosed motor housing – it protects your tool from flying chips and debris.
And if you’re asking “Can I cut metal with a circular saw?” or “Will a circular saw cut metal?” – yes, absolutely. You just need the right blade and setup.
2
What types of metal can you cut?
A metal cutting circular saw is surprisingly versatile – especially when paired with the right blade.
You can cut:
- Aluminium – great for sheets, bars and sections.
- Copper and brass – soft metals that cut cleanly.
- Mild steel – if it’s not too thick.
- Thin stainless steel – with a diamond blade and a steady hand.
It works best on:
- Flat bar
- Light box section
- Sheet metal (when secured properly)
Not great for:
- Thick steel bar or plate – you’re better off with a chop saw or bandsaw.
- Corrugated or perforated metal without support underneath.
What size circular saw is needed for sheet metal cutting? Most standard 7 1/4" saws will handle light sheet work, but always check your blade’s depth rating first.
3
Choosing the right blade
This is where things can go wrong fast – so get it right. Only use a circular saw blade for cutting metal – never a wood blade.
Your best bets are:
- Carbide-tipped blades – perfect for non-ferrous metals like aluminium and copper.
- Diamond-tipped blades – needed for stainless and tougher steels.
- 7 1/4" metal cutting blades – ideal for most handheld circular saws.
Look for labels like metal skill saw blade, metal cutting circular or circular saw metal cutting. Brands like Diablo, Milwaukee and Lenox make popular options.
The right blade keeps your cut smooth, protects your tool and most importantly – keeps you safe.
4
Prep before cutting
Before you switch on your metal-cutting circular saw, take a minute to get everything in place. A clean setup leads to a cleaner cut – and fewer problems down the line.
- PPE first – Always wear safety goggles, gloves, hearing protection and long sleeves. Cutting metal with a circular saw metal blade throws out hot chips at speed – you don’t want those hitting bare skin.
- Mark your cut – Use a marker or scoring tool to draw a clear, visible line on the metal.
- Clamp it down – If the metal moves, your cut suffers. A secured workpiece is safer and more accurate.
- Blade depth – Set your saw so the blade only goes 6mm (¼ inch) beyond the metal’s thickness. More than that just increases kickback risk.
- Support the metal – Rest the sheet or section on sawhorses or rails so the blade has room underneath.
Got your metal saw blade fitted and everything locked down? You’re ready to roll.
5
How to cut metal with a circular saw: Step-by-step
Let’s break down the basics of cutting metal with a circular saw:
- Power up safely – Plug in your saw (or make sure your battery’s charged). Keep the cable well out of the cutting line.
- Line it up – Use a guide rail if you have one. Align the blade with your marked line – but keep it clear of the metal to start.
- Spin it up – Squeeze the trigger and wait for the metal circular saw blade to reach full speed.
- Make the cut – Push the saw steadily forward. Don’t force it – let the blade do the work.
- Apply fluid if needed – For long or thick cuts, use cutting fluid to keep heat down and preserve blade life.
- Finish clean – Release the trigger, let the blade stop fully, then lift the saw away.
- Handle with care – The blade and cut edge will be red-hot – don’t touch either right away.
Cutting sheet metal with a circular saw? These steps work just as well – just double-check your support setup to avoid warping or wobble.
6
Common mistakes to avoid
Even the best metal cutting circular saw won’t save you from these classic errors:
- Using a wood blade – A major no-no. Use a circular saw blade metal cutting type every time.
- Skipping clamps – Loose metal = kickback risk.
- Wearing the wrong kit – Flying shards are no joke.
- Rushing the cut – Pushing too hard causes poor cuts, burnt edges and blade damage.
Or let us handle it
Not got the tools? Don’t fancy dealing with blades and sparks? We get it. That’s why we offer a free cutting service at The Metal Store.
We’ll take the hassle out of cutting – and it won’t cost you a thing. Whether it’s aluminium, mild steel, brass or stainless, we’ll cut it to size and get it delivered to your door.
We also offer 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.
Why mess about with saws when we can do it for you? Order your cut-to-size metal from The Metal Store today – and skip the sparks.
