When working with metal, having the right snips can make all the difference in getting clean, precise cuts. There are a few main types of snips that are commonly used for cutting various metal materials.
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Tin Snips
Tin snips, also known as aviation snips, are scissors-like tools designed specifically for cutting thin sheets of metal like tin, aluminum, brass, and other soft metals. They come in 3 main varieties:
- Straight cut tin snips – Ideal for cutting straight lines and gradual curves
- Right cut tin snips – Best for making tight right angle cuts
- Left cut tin snips – Best for tight left angle cuts
Tin snips utilize very sharp blades that cut as the two handles are pressed together using the hand muscles. The compound leverage design allows the blades to exert great force and cut through metal up to 16 gauge mild steel. Tin snips can cut curves and circles by rotating the material.
Key Features of Tin Snips
- Sharp precision blades – Usually made of hardened carbon steel for durability
- Ergonomic handles – Provides grip and leverage for hand cutting
- Blade alignment – Ensures a flush, even cut
- Adjustable pivot bolt – Lets user increase cutting pressure as needed
- Safety latch – Helps protect blades when not in use
Hacksaw
A hacksaw is a handsaw that has a thin blade held rigidly in a frame. The rigid frame allows the user to apply great force to cut through metal with the sharp teeth on the blade. Hacksaws are commonly used to cut and shape bars, rods, tubing, and other metal objects with precision.
The hacksaw blade is replaceable and comes in various sizes and tooth configurations:
- 18-32 teeth per inch for cutting thicker/softer metals
- 32-56 teeth per inch for thinner/harder metals
The most common blade material is high carbon steel, which provides hardness to cut metal, while also being flexible to turn corners. Other blade materials include tungsten carbide and cobalt steel for increased durability.
Key Features of Hacksaws
- Adjustable frame – Lets user tension blade for optimal cutting
- Comfortable handle – Provides grip and control when sawing
- Quick blade release – Allows fast blade changes
- Stroke limiter – Prevents overextension of blade to protect frame
Bolt Cutters
Bolt cutters are large, compound lever tools for cutting hard materials like metal bolts, chains, padlocks, rebar, and wire. The long handles provide considerable leverage to amplify the cutting force applied by the user.
There are different types of jaws to cut different things:
- Flat jaw – Best for cutting padlocks, chains, and wire
- Round jaw – For cuter rebar, nails, and rivets
- Concave jaw – For bending or crimping metal
The size of bolt cutters is described by the maximum bolt diameter they can cut. Common sizes range from 12 inches for small jobs up to 36 inches for cutting thick, hardened steel.
Key Features of Bolt Cutters
- Hardened steel jaws – Maintains sharp cutting edges
- Compound leverage – Multiplies hand force for power
- Pivoting joint – Lets jaws align correctly on object
- Cushioned grips – Reduces hand fatigue from pressure
- Automatic jaw spacing – Self sets optimal size for material
Angle Grinder Cutting Wheels
An angle grinder is a useful power tool for cutting metal when you need to make lengthy cuts or remove a lot of material quickly. Grinders use replaceable abrasive discs called cutting wheels that come in variety of styles for different uses.
Common types of metal cutting wheels include:
- Cut-off wheels – Thin discs for straight cuts in sheet metal or bolts
- Depressed center wheels – For grinding, notching, and gouging metals
- Diamond wheels – Coated in diamond for cutting hard materials
- Flap discs – Flexible for smoothing burrs and weld seams
Cutting wheels designed for metal range from 115mm to 230mm (4.5″ – 9″) in diameter. Thinner wheels cut faster but may bind in deep cuts. Always select the right wheel for the material thickness.
Key Features of Angle Grinder Cutting Wheels
- Reinforced core – Provides durability at high speeds
- Silicon carbide grit – Aggressive cutting for most metals
- Layered fiberglass – Prevents disc shattering while in use
- Built-in arbor size – Matches angle grinder spindle mount
- Maximum rpm rating – Do not exceed wheel limitations
Oscillating Multi-tools
Oscillating multi-tools are compact power tools that vibrate a triangular saw blade back and forth. They are ideal for detailed metal cutting in tight spaces and curved cuts.
Common blade types for metal cutting include:
- Bi-metal blades – For hard metals or nail embedded wood
- Carbide grit blades – Quickly grooves metals prior to bending
- Fine-tooth blades – Leaves clean finishes on light metals
Oscillating blades come in varied lengths from 1″ to 7″. Variable speed settings allow matching the amperage to different cutting needs.
Key Features of Oscillating Multi-tools
- Tool-free blade change – Allows rapid blade swaps
- Dust extraction attachment – Helps control metal shavings
- Rubberized grip – Provides comfort and slip resistance
- Cordless convenience – Enables cutting mobility
- Plunge cutting action – Lets blade dig into material
Nibblers and Shears
Nibblers, also called electric shears, use a punch and die system to cut sheet metal by “nibbling” away small sections. This allows following contours and leaving a clean, burr-free edge.
Hand nibblers are manually operated, while electric nibblers are faster, more powerful, and easier for longer cuts. Nibbler capacities range from 16 gauge to 10 gauge mild steel.
Some key benefits of nibblers and shears:
- Precise control for detail work
- Variable speed on electrics
- Cuts left or right direction
- Low maintenance with no blades
- Less metal distortion than torches
Key Features of Nibblers and Shears
- Hardened cutting dies – Maintains sharpness
- Depth adjustment – Controls cut thickness
- Ergonomic design – Comfortable extended use
- Built-in deburring notch – Offsets edges for clean finish
- Cuts overlapping steel – No need to separate sheets
Plasma Cutters
Plasma cutters are electric tools that create a very hot, directed plasma arc between a constricting nozzle and an electrode. This lets them cut rapidly and accurately through metal using the heat of the plasma.
Handheld plasma cutters offer portability, while CNC plasma tables provide automation. Useful for both handheld and CNC cutting, plasma cutters excel at:
- Cutting mild steel up to 1 inch thick
- Cutting stainless steel up to 1/2 inch thick
- Cutting aluminum up to 3/4 inch thick
- Leaving smooth, clean cuts with little distortion
Plasma cutters require an air compressor and plasma cutting consumables like tips, electrodes, and shields. CNC plasma tables require CAM programming software.
Key Features of Plasma Cutters
- Precision cutting height control
- Minimum metal distortion
- Narrow heat-affected zones
- High duty cycles for continual use
- High cutting speeds up to 500 IPM
- Dragon cutting reduces edge preparation
Laser Cutters
Laser cutting utilizes a high power, focused laser beam to melt and vaporize metal. This is a non-contact process that provides precise, clean cuts at high speeds. The laser head moves along pre-programmed paths to cut complex shapes.
The most common lasers for cutting are CO2 and fiber lasers. Typical capabilities include:
- CO2 laser – Up to 1 inch mild steel
- Fiber laser – Up to 1/2 inch stainless steel
- Very small kerf and heat-affected-zone
- Cuts at speeds exceeding 3000 IPM
- High accuracy down to 0.005 inches
Laser cutting requires CAD/CAM software and the metal may need special surface coating or oxidation prevention depending on the material.
Key Features of Laser Cutters
- Non-contact process – No tooling required
- Narrow kerf – Minimal material waste
- High precision – For refined parts and assemblies
- Low force – Does not distort thin metals
- Clean, polished edges – Reduced secondary processing
Waterjet Cutters
Waterjet cutters direct an extremely high-pressure jet of water mixed with abrasive particles to cut through metal. They are capable of precisely cutting all types of metal from delicate materials to thick steels.
Intensifier and direct drive are the two pump types providing water pressure up to 94,000 PSI. Waterjets excel at cutting:
- Any metal from aluminum to titanium
- 1 inch thick stainless steel
- Precise, complex shapes with no heat affected zones
- Stacked, mixed, or painted materials
Abrasives for waterjets include garnet and aluminum oxide. Use CAD/CAM software to convert designs into waterjet machine paths.
Key Features of Waterjet Cutters
- No heat or melting effects
- Minimizes hardened edge or warping
- No sparks or fumes
- Delicate cutting of thin metals
- Converts easily to other tools
Comparison of Metal Cutting Tools
There are some key differences between the common metal cutting tools in terms of capabilities, applications, and benefits:
| Tool | Cutting Capabilities | Best Applications | Key Benefits |
|---|---|---|---|
| Tin Snips | Up to 16 gauge mild steel | Thin sheets, ducts, seams | Inexpensive, portable |
| Hacksaw | Bolts, rods, pipes | Straight cuts, shapes | Simple, versatile |
| Bolt Cutters | Hard materials up to 1/2 inch | Chains, padlocks, rebar | Powerful, durable |
| Angle Grinder | Cut-off discs for thick steel | Large volume removal | Fast, portable |
| Oscillating Tool | Sheet metal, light sections | Detail work, curved cuts | Compact, precise |
| Nibbler/Shear | Up to 10 gauge mild steel | Contours, sheet metal | Controlled, clean cuts |
| Plasma Cutter | 1 inch mild steel, 1/2 inch stainless | Automated production | Fast, automated |
| Laser Cutter | 1 inch mild steel, 1/2 inch stainless | High precision parts | Accurate, fast, automated |
| Waterjet Cutter | Any metal up to 1 inch thickness | Mixed material stacks | Precise, no heat effects |
Choosing the Right Metal Cutting Tool
Selecting the best metal cutting tool involves considering factors like:
- Type and thickness of metal
- Cutting precision needed
- Cutting speed requirements
- Power source availability
- Portability needs
- Quality of cut wanted
- Production volume
- Complexity of cuts
- Cost and budget
Understanding the capabilities of the different metal cutting tools allows matching the right tool to the application. Consulting experienced metalworkers can also help identify the most suitable choice.
Conclusion
Having the proper metal cutting tool is essential for efficiency, safety, and quality results. The variety of snips, saws, shears, and powered cutters makes it possible to cleanly and accurately cut any type of metal for any job. Experienced metalworkers know how to select and expertly handle the best cutting tool for each application.