Metal Cutting: Techniques, Tools, and Safety for Beginners

Metal is an incredible material it offers a way to make components that have extremely high strength, hardness and durability properties, at relatively low cost. It can be bought in many different shapes and sizes, and is easily joined, shaped and formed, with the right tools.

In this article, we’ll take a look at some of the ways metals can be cut, what tools are used, and what the potential pitfalls are.

What Is Metal Cutting

Metal, like most materials, comes in a variety of shapes and sizes. From flat sheet, to round tube, to large beams or column sections. Whilst many retailers offer a cutting service, in some cases the raw material will need to be shaped or cut to length on site, before work can begin.

Some of the key benefits of using metal as a construction material – strength and durability – are also the cause of many difficulties when first working with the material, namely its resistance to cutting, drilling, and bending, especially if using the incorrect tools.

Why Metal Cutting Matters in DIY and Industrial Applications

Other materials, such as wood, card, and certain plastics, can easily be cut with hand tools, regardless of the thickness or number of cuts to make. Metal on the other hand, can present a serious challenge unless you have appropriate tools and methods.

In order to take your supplied lengths or sheets of material and make something functional out of them, they probably need to be cut to shape. The difficulty of this will depend on how many pieces need to be cut, the accuracy required, and the thickness or size of the stock material.

Common Metal Cutting Techniques

There are numerous methods of cutting metal, ranging from simple, slow processes to large scale industrial machines.

Hand tools for cutting metal

• Hacksaw – One of the most ubiquitous workshop tools, a hacksaw with a fine-tooth metal blade can cut most sections, provided you have the strength and time
• Chisel – in a pinch, a chisel, vice and hammer can be used to shear sheet and bar
• Metal snips – working much like scissors, these can be quite effective for cutting both straight lines and curves in thin sheet metal
• Benchtop shear – These simple but effective devices can cut surprisingly thick metal when maintained and used correctly
• Bolt cutters – if accuracy and precision are not a priority, bolt cutters can be an effective way to crop round bar, small square bar or even sheet

Power tools and machines for cutting metal

• Angle grinder – most workshops and garages have one – they are very versatile, but need to be used with care to prevent injury or inaccurate cutting
• Guillotine – hydraulic or mechanical guillotines make light work of making straight cuts in sheets, anywhere from 1m to 10m+
• Plasma cutter – both hand and CNC controlled plasma cutters are great for cutting all sorts of metals. They use an electrical arc and high pressure air to cut quickly and efficiently
• Bandsaw or cold saw – for cutting lengths of material such as pipe, angle iron, beams, cold or band saws are perfect, giving a clean, square, accurate cut
• Power shears – similar to the manual snips, power shears can be great for making curved parts from sheet metal quickly

Choosing the Right Metal Cutting Tools

Knowing how to choose the right tool for the job comes from knowledge and experience, both of metal cutting in general, and previous work with the specific size and shape of material needed.

These are the main determining factors for what tool to use:

Size and form factor

Some machines and tools are not multifunctional and perform best on their specific type of material:

• Flat sheets are best cut with shears, guillotines, or plasma cutters
• Bars such as round and flat can be cut with a hacksaw, grinder, or band saw
• Hollow sections such as angle iron, box section and tube are best cut with a cold saw or band saw, but can be done with a hacksaw or angle grinder

Speed

If you have a lot of cuts to make, an automated machine may be the most economical way to go, this will give cost effective cutting and repeatable accuracy.

Failing that, a power tool such as a band saw or angle grinder will be a lot less tiring than a hacksaw!

Accuracy

If your parts need to be accurate above all else, then well-maintained machines such as hacksaws are best for long sections such as pipe or angle iron, and laser cutting or CNC controlled guillotines for sheet metal.

Versatility

If you need to make cuts in the field, with tools that you can carry in your truck or in a tool bag, then your options are significantly limited. Access to an electrical hookup is also a determining factor.

Keeping a hacksaw (with spare blades), an angle grinder (with various cut off wheels) and a pair of snips with you should cover most bases. Also, cordless band saws are now made by most mainstream power tool brands, they can be invaluable.

These tools can be used to make accurate cuts if care is taken, but they will not be the fastest methods!

Essential Safety Tips for Metal Cutting

• Always wear appropriate personal protective equipment. What that is depends heavily on the type and location of the work.
• Plan out the job. Figure out where the offcuts or parts will drop to when cut, where the power cord will end up, and where any sparks or hot chips will land
• Warn others around you. Either warn anyone likely to come near or cordon off areas when using grinders and other spark-producing tools.
• Keep hands and arms away from anything moving or hot. A bandsaw blade can snag a shirt sleeve or glove in an instant, and grinding discs can be extremely hot after use.

Mistakes to Avoid When Cutting Metal

• Measure twice, cut once. Always double check your markings, tape position and workings before making important cuts
• Pay attention to machine limitations. Finding out halfway through a cut the material is too large for your machine or cutting disc can cause huge problems
• Not accounting for the blade thickness. Ensure you are cutting on the scrap side of your mark, or have accounted for the blade thickness.

Conclusion

Hopefully, this guide will help you to make effective, safe and accurate cuts in all sorts of metal products, for fabricating, construction and more. Remember to prioritise the safety of yourself and others, and work methodically, speed will come with experience!

If you need lots of material cutting, or want a more cost effective way of acquiring cut-to-length materials, check out Metal Supermarkets cut to length service, operating from over 125 locations across North America.