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Choosing metal cutting band saw

Sawing is a science – a multitude of influencing variables and their interaction determine which result is achieved in sawing applications. You may need different types of saws.

The advantage of these saws lies in their accuracy and durability, as well as in the certain degree of automation. Angles, square tubes, or round tubes as well as any other metal profiles can be precisely cut with a metal cutting band – even mitered. The latter in particular is a key advantage of the metal cutting band.

We would like to help you find the best metal cutting band for you.

metal cutting band chosing

What is a band saw?

Band saws are special saws and roughly speaking a mixture of chain saw and jigsaw. The central functional element of a band saw is an endless saw band, which is driven like a V-belt. At one point, the saw is open – at the saw table. This is where sawing can take place. Due to the lack of vibration, band saws can be used to make very precise cuts, especially short straight or curved cuts.

Before buying, it’s important to consider how much and how often you’ll actually use the machine. For the occasional or even only use, of course, it does not have to be a professional, powerful metal band saw.
So, first and foremost, you should compare the technical details of the saws before you buy them. Factors like belt speed, weight, and performance are basic things you should keep an eye on.

How does a metal cutting band work?

A metal band saw works in principle like its woodworking relatives. A ring-shaped metal band saw blade is driven by a motor, rotates and is guided over two rollers. This ensures an uninterrupted cut because the saw blade runs continuously in a straight line. The sawing process is not only very precise but also very easy to handle.

You can create straight as well as curved or circular cuts. You can also cut a wide variety of metal workpieces. It makes no difference what type of metal is to be cut, be it iron, copper, steel, or aluminum.

Can cut vertically and horizontally with a metal band saw?

This depends on the model. Most metal bandsaws for home use are designed exclusively for horizontal cuts. However, the metal band saw blade can be used at different angles of inclination.
A vertical cut is only possible with very few models and this then applies anyway to professional band saws, which are primarily used commercially. These are then also usually supplied with a corresponding table to provide the necessary support.

Types of metal cutting band

Metal band saws are offered in different equipment and in different power ratings. Basically, the models can be divided into the following categories.

  • Metal cutting band saws without substructure
  • Metal cutting band saws with substructure

Metal cutting band without a substructure

For normal use in the DIY sector, the smaller models without a substructure, so-called manual bandsaws, are the first choice.
These are often smaller versions that have a lower weight than the professional models and are also somewhat weaker in terms of power.

Advantages Disadvantages
Light weight Not 100% accurate
Easy to transport No inside cuts possible
Suitable for small workpieces
Relatively inexpensive

The weight is about 20 kg and the power level ranges from 600 to 800 watts. The advantage of these devices is that they are easy to carry and transport, and therefore can be used in any place.

Metal cutting band with a substructure

If you use metal band saws professionally or are already a professional in metalworking, metal band saws with substructure are interesting for you.

Advantages Disadvantages
Clean and precise cuts Semi-professional machine quite expensive
Different angles adjustable No inside cuts possible
Also, suitable for larger workpieces Difficult to transport
Filigree cuts possible due to fine saw blade
Cutting of solid material possible

This type of saw is partially equipped with a separate cooling system and is even suitable for cutting solid material. However, you need a mains voltage of 400V for these models, which is why they are also used more in the commercial sector.

metal cutting bandsaw

Criteria of choice metal cutting band

With portable, smaller models, so-called hand band saws, horizontal cuts are always possible. If you also need to cut vertically, you should look for professional machines.

In the following, we will show you what to look for in the individual features and how you can compare and evaluate different band saws. This will make it easier for you to decide whether a particular device is suitable for you or not.

Type

Essentially, band saws can be divided into two categories. For the do-it-yourselfer, the smaller models, which are also often referred to as manual band saws, are the first choice. Nevertheless, the larger metal band saws with a substructure are also interesting for advanced hobby DIY or for the professionals among DIY.

Models without a substructure are so-called manual band saws. These are usually smaller versions that do not necessarily have to be used stationary. These bandsaws have a weight of around 20 kg and can be set up in any location.

However, it is important that the location is stable and straight. The power of each machine varies from manufacturer to manufacturer. On average, the wattage is around 800 watts. The saw bandwidth is 13 millimeters on average. Here, too, different angles can be set, and you can choose from various designs.

Models with a substructure are sometimes equipped with a separate cooling system and are suitable for cutting solid material.

A mains’ voltage of 400 volts is required for operation, so these large editions of metal band saws are more likely to be used in the commercial sector. Regulation of the speed is also possible, as well as the setting of the desired angle.

Weight

Especially in the DIY sector, it can be important that the device is not so heavy.

Even among DIY machines, a model can weigh as much as 60 kilograms. This is, of course, unfavorable if you want to be mobile. A machine for mobile use should not weigh much more than twenty kilograms so that you can get it from A to B well. Perhaps your chosen model can also score with carrying handles.

If you use the band saw stationary, or it is important to be able to cut solid material, the device may of course be heavier. Machines with cooling systems, in particular, can weigh around 300 kilograms.

Power

The machine requires sufficient power for a good cutting result. The power of the motor is expressed in watts. The higher the wattage, the stronger the motor power. Entry-level machines start at 400 watts. Professional machines can put a good 2,000 watts on the plate.

Only with enough power can you be sure that your metal band saw will cut large or thick pieces. To find the right power, consider whether you plan to saw a lot of solid pieces.

Belt and cutting speed

The band and cutting speed go hand in hand. You can only saw slowly if the band is slower. Often the speed is regulated by setting the speed. The rule here is up to three steps.

This option is good if you want to process different materials. So good results are easier to achieve. There is a suitable saw blade for every material. Here we explain what you need to look out for in a saw blade.

Saw blade length

The length of the saw blade is specified by the manufacturer. This must be because the saw band must be clamped exactly. If the saw band is too short or too long, it will not clamp.

Saw band width

If it is a horizontal machine, the width is already specified and is usually 13 millimeters. With vertical machines, different widths are possible for the saw band. Here, the wider the saw band is, the more stable the saw band will be.

If you want to cut contours, the smallest radius to be cut limits the width of the saw band.

Saw band thickness

There is a rule here. If it is a resharpenable band, the thickness of the band should not exceed 1/1000 of the roll diameter. This means, for example, if the roll is 50 cm in diameter, the saw band should not be thicker than 0.5 mm.

If you were to choose a thicker band in the example calculation, it could break quickly because hairline cracks would occur in the tooth base. If you use a disposable band, it may be thicker than 0.5 mm, as these bands are constructed differently. Disposable bands cannot be resharpened. The thicker the band saw blade, the thicker the workpiece can be.

Horizontal and vertical sawing

In horizontal sawing, there is additional pressure, for example, from a hydraulic damper. This type of saws is mainly used for bars. Vertical saws perform the surface cut, similar to what you might know from woodworking.

Many metal band saws combine both types of sawing. This is especially practical for do-it-yourselfers who use both, because they only need one device and not two.

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