Guide to Metal Cutting Tools | Best Power Tools to Cut Metal

Learn about the best metal cutting tools, as well as the most suitable methods for cutting common materials like metal sheets, studs, and metal pipes.

The quantity, quality, and experience of your workpieces all play a major role in choosing the best metal cutting tools. A different metal cutting tool is required for different types of cuts, for example, a hole saw for a circular cut, a chop saw for a straight cut, and rotary tools for precision and a small cut.

To help you select the best metal cutting tools, we will discuss all of them along with their applications in this post.

Read More: 7 Best Ways to Cut Metal Fast

Best Power Tools to Cut Metal

Power tools are used for almost all metal fabrication and industrial work. These cutting tools are required to perform numerous tasks such as grinding, polishing, drilling, cutting, sharpening, and sanding of metals. The following are the best metal cutting tools are:

1. Angle Grinder

An angle grinder is a standard metal cutting tool for using cut-off wheels.

The angle grinder, often known as a hand grinder, is most crucial for cutting metal. For angle grinders, the 4-1/2 cutting wheel is widely utilized.

An angle grinder cuts metal fast and efficiently. Removing rough cuts, weld spatter, and rust is a common application of an angle grinder.

Pros

• Highly versatile tool
• Capable to work on small areas
• Compatible with different cutting wheels and material surfaces

Cons

• Not good to obtain fine and finished cuts
• High pressure can break wheels
• Irritating noise and kickback

2. Reciprocating Saw

Reciprocating saws are great for cutting metal.

Reciprocating saws, often called oscillating saws, are the most widely used and useful tool for cutting metal. They can cut metal efficiently and quickly. They are also one of the strongest saws available. Standard metal reciprocating saw blades are compatible with the saw tool, which is used to cut pipes, PVC, wood, and metal sheets.

Pros

• Cuts through almost anything
• Powerful and fast cutting
• Perform several functions

Cons

• Quite rough and inaccurate
• Its large blade can cut wires
• No smooth cuts

3. Circular Saw

Circular saws are a perfect power tool for cutting metals. They can effectively cut metal, wood, hard steel, stone, and ceramic tile with a TCT saw blade.

Pros

• Provides clean-cut-through metals
• An easily available and accessible tool

Cons

• Can't cut curves
• Saw blades are expensive & break easily
• Noisy tool

4. Hole Saw

Hole saw cutters or hole cutting tools are made to be extremely tough to cut through metals. They are capable of resisting high temperatures produced by cutting through a number of popular metals, including stainless steel. Bi-metal 5 inch hole saw is ideal for creating holes in timber and wood sheets. Apart from the metal hole saw can easily cut through wood, tile, concrete, and glass.

Pros

• Multipurpose cutting tool
• Cutting a right circle
  
• Less expensive

Cons

• Not a versatile tool

5. Cut-Off Tool

This metal cutting tool uses cut-off wheels and resembles an angle grinder.  For general-purpose cutting of metals such as aluminum, carbon steel, stainless steel, and others, cut-off tools are perfect. They are designed to provide a quick and accurate cut, also last longer, and perform better than any traditional tool. A cut-off tool is useful to work in small areas where other large tools can not work. 

Pros

• Compact and easy to handle
• Can work in a narrow space
• Ideal for removing weld splatter

Cons

• Too small for more extensive applications
• Can’t cut through thick material

6. Plasma Cutter

A popular method of cutting metal is plasma cutting. It uses the heat from an electric arc to cut through the material with minimal effort, producing precise, clean cuts.  Plasma cutting might be a great choice for people searching for a quick and affordable solution to cutting materials. Plasma cutting machines, also known as plasma cutters, use a plasma stream to provide energy. An external power source generates an electric current that gives the gas flow enough energy to ionize it and transform it into a plasma arc. Once the metal has been melted by the plasma arc, it is first expelled from the workpiece.

Pros

• This method is perfect for complicated and detailed work because it can help produce clean cuts with no thermal distortion.
• The approach is significantly faster compared to the numerous old ways. Each could efficiently finish the cutting and save time.
• Compared to other conventional methods, this contemporary methodology is relatively inexpensive and requires minimal operating expenditures.
• Compared to oxygen-based cutting, which has an explosive risk, the devices use inert gases, which are far safer. Depending on the strategy, the availability of parts like the CNC plasma table can also be quite beneficial.

Cons

• It is limited to conductive materials.
• Using metals thicker than 150mm, or about 6 inches, is not recommended.
• Bright flashes from cutting could damage the eyes.
•  Using low-life consumables like electrodes and nozzles could be expensive.

7. Laser Cutter

The most common use of laser cutters is cutting two-dimensional objects. They melt or burn metal using a narrow laser beam, providing precise and clean cuts. The manufacturing industry extensively uses laser cutters, and they can also be applied to creative tasks. This widely used method is effective in producing precise two-dimensional components in large quantities.

Pros

• The accuracy and precision of laser cutters are extraordinarily great.
• The procedure may be completed at high speeds, albeit the rates vary based on the material's thickness and nature.
• With minimal operator interaction, the process is highly automated and may incorporate material handling devices. 
•  Laser cutting is often a clean procedure, even if it requires cutting fluids or other chemicals.
• No extra work holders or tooling are needed. 
• After being cut, they typically don't need much additional effort.
• Capable of cutting a variety of materials.
• Able to cut and engrave materials.

Cons

•  Lasers can only cut things up to a certain thickness. Usually, the maximum is 25 mm. 
• Ventilation is necessary because some compounds release harmful fumes. 
• It requires a lot of electricity.
• Some laser systems, including CO2, require more expensive replacement parts regularly. 
• The procedure needs to be enhanced to prevent discoloration or burning.

8. Band Saw

Band saws are tools used for cutting materials. You can get the precise cut you need with its broad, toothed blade. In order to make exact cuts that meet the user's demands, band saws work by sinking their teeth into metal, wood, or other materials. The kind of blade you use will determine the kind of cut you get. But if the blade is smaller, the curves will be tighter. Blades for woodworking that have fewer teeth work better.

Pros

• One of a band saw's greatest advantages is its ability to make accurate cuts. With the correct blade, you can produce precise angles, sharp edges, and complex curves.
• This tool can cut other materials like wood, plastic, etc., in addition to metal. It is mainly used in the metalworking and furniture manufacturing sectors.
• Many modern band saws have safety features that reduce the likelihood of accidents. These features include automated shutdown, safety switches, and blade guards.
• With its ability to make precise and timely cuts, a band saw can help you work more efficiently.  When working on a project that requires a lot of accurate cutting, this is especially true.

Cons

• One of the primary drawbacks of a band saw is its cost. This instrument could be pricey, particularly if you're looking for a high-end model.
• Due to their considerable size, these tools require a distinct workspace.
• If you have your workspace, a band saw might be OK, but if you work in a shared office or are sensitive to noise, it might not be the best option.