A jigsaw is a versatile power tool used for making curved or irregular cuts in various materials like wood, plastic, and thin sheet metal. Many DIYers wonder if an ordinary jigsaw can cut through thicker metal pieces like steel or aluminum. The short answer is yes, you can cut metal with a jigsaw under certain conditions. However, there are limitations on the thickness and hardness of metal a basic jigsaw can handle. Understanding the capabilities and ideal uses for jigsaws will help you determine if one can work for your metal-cutting needs.
Page Contents
How Jigsaws Cut
A jigsaw cuts materials using a thin, reciprocating blade that moves up and down very fast, between around 500 to 3,100 strokes per minute. This rapid oscillating movement of the sharp blade edges helps it shave away material as it moves forward through the workpiece. The key factors that affect a jigsaw’s cutting performance are:
– Blade design – Different TPI (teeth per inch) and tooth shapes (like aggressive corrugated teeth) optimize cutting in various materials. More TPI usually gives a smoother cut.
– Blade orbit – This refers to the shape of the blade’s path as it reciprocates. Some jigsaws use orbital action which means the blade shifts slightly sideways as it moves up and down for faster cutting. Orbital cutting however, reduces precision.
– Speed control – Having variable speed control lets you match the blade’s optimal cutting speed to the material you are cutting. Harder materials need slower speeds to avoid rapid wear or breakage.
– Power – Higher amperage jigsaw motors can sustain blade speeds better when meeting heavy resistance from thicker or harder materials.
– Base plate and guides – Sturdy metal base plates and roller guides on the shoe help keep the saw steady and the blade perpendicular as you cut. This improves control and accuracy.
Cutting Capability
Most consumer-grade jigsaws are designed for cutting wood and may be able to handle thin sheet metals or soft alloys like aluminum. Here are some guidelines on cutting different metal types:
Aluminum
Softer metals like aluminum can be cut easily with a basic jigsaw using the right blade. Choose a blade with fine teeth (at least 24 TPI) to get a clean cut and avoid tearing the metal. Reduce the speed if needed and use smooth, controlled feed pressure. Lubricating the cut line may help for longer cuts. Up to about 3/16-inch thick aluminum can be cut with a good jigsaw.
Steel
Mild steel up to about 10 gauge (1/8 inch) may be possible to cut with a sturdy jigsaw but it requires patience and the correct technique. Use a bimetal blade designed for cutting ferrous metals with the lowest speed setting and minimal orbital action. Apply smooth, steady pressure without forcing the saw to prevent premature blade wear. Expect to go through multiple blades on longer cuts.
Stainless steel
Cutting stainless steel with a jigsaw is very difficult and not recommended. The hardness of the material quickly dulls regular jigsaw blades. Even using specialized abrasive cutoff wheels, you will likely need a more powerful tool like an angle grinder for stainless steel.
Cutting Tips
Follow these tips when cutting metal with a jigsaw for best results:
– Secure the workpiece to prevent vibration and slipping while cutting. Use a bench vise or clamps on a sturdy work table.
– Mark cut lines clearly and use a straightedge to help guide the jigsaw smoothly.
– Hold the saw firmly and upright without twisting the blade when starting cuts.
– Use cutting fluid or lubricant like WD-40 when cutting longer than a few inches.
– Make relief cuts when cutting out interior shapes. Back the blade out periodically to clear metal shavings.
– Use the slowest speed and no orbital setting to reduce blade wear and overheating.
– Take your time and don’t force the saw during cuts to avoid premature blade breakage.
Jigsaw Features for Metal Cutting
Look for these helpful features if you plan to use a jigsaw regularly for cutting thin metal:
Adjustable speed
Variable speed control (ideally in the 0-3,000 SPM range) allows you to find the optimal cutting rate for different materials. Slower speeds are needed for thicker and harder metals.
Tool-free blade changes
Quick and easy blade replacement is helpful since metal cutting operations can require multiple blade changes. Tool-free mounting makes this faster.
A button to lock the saw in the on position helps reduce finger fatigue on longer cuts. Look for a “soft start” function to smoothly ramp up blade speed at start-up as well.
Blade stabilization
Features like counterbalancing mechanisms or gyroscopic blade stabilization can help combat some vibration and improve cutting precision.
Roller shoe guides
These guides on the saw’s base plate help reduce friction when guiding the jigsaw in straight cuts. This enhances control and reduces wear on the blade.
Best Blades for Cutting Metal
Using the right jigsaw blade is critical for successfully powering through metal. Some good options include:
Bi-metal blades
These have teeth made from high speed steel for durability, along with a softer steel body that allows some flexibility. Great for cutting steel up to 1/8 inch thick.
Carbide grit blades
The abrasive grit on these blades helps them grind through tough metals without overheating. Best for stainless steel or hardened alloys.
Fine tooth HCS blades
High carbon steel allows smaller teeth for smooth cuts in softer metals like aluminum or brass. Look for 24+ TPI.
Coarse tooth HCS blades
Larger teeth chip away thicker copper and other non-ferrous metals efficiently. These are more prone to bending than fine blades.
| Blade Type | Best Uses |
|---|---|
| Bi-metal | Steel up to 1/8 inch |
| Carbide grit | Stainless steel, hardened alloys |
| Fine tooth HCS | Smooth cuts in soft metals |
| Coarse tooth HCS | Rapid cutting of non-ferrous metals |
Jigsaw Metal Cutting Technique
Follow these steps for safe and effective metal cutting with a jigsaw:
Step 1 – Choose blade type
Select an appropriate blade for the metal you are cutting as recommended above. The blade must be rated for cutting metal.
Step 2 – Install blade correctly
Make sure teeth are facing down and oriented to cut on the upstroke. Insert the back end fully into the chuck and tighten retaining screws.
Step 3 – Adjust speed
Consult your tool’s manual and set the variable speed to the proper range for metal. Start at the lowest setting first.
Step 4 – Secure workpiece
Clamp metal sheet or piece firmly to a worktable. Use sturdy bar or C-clamps and check it does not shift.
Step 5 – Mark cut lines
Use a permanent marker and straightedge to draw cut lines if needed. This helps guide the jigsaw.
Step 6 – Start cut properly
Hold the front shoe of the jigsaw flat on the workpiece as you start. Allow blade to reach full speed before starting cut.
Step 7 – Cut slowly and steadily
Apply smooth pressure downwards in the direction of cut. Let the blade do the work without forcing or twisting the saw.
Step 8 – Back out blade periodically
Retracting the blade clears chips and prevents overheating, especially on longer cuts.
Step 9 – Watch for blade dulling
Inspect the blade edge occasionally. Replace blades as soon as cutting performance drops off.
Conclusion
While jigsaws are primarily designed for woodworking applications, they can cut thin sheet metal, aluminum, and steel with the right technique. Understanding the capabilities of your saw along with using specialized blades allows you to adapt this versatile tool for select metal cutting jobs. However, a jigsaw has limits when it comes to material hardness and thickness capacity compared to metal-specific tools like a reciprocating saw, angle grinder, or plasma cutter. Assess each cutting job and make sure a basic jigsaw has the power and durability to complete the necessary cuts in metal. With patience and care, DIYers can use jigsaws to take on small-scale metal fabrication tasks.