Cutting metal with a bandsaw can be super satisfying, but only if you’ve got the right blade. A dull or incorrect blade leads to frustration, wasted material, and potentially even damage to your saw. I’ve spent way too much time wrestling with the wrong blades, so I decided to put together a list of the best ones for different metal-cutting tasks. This guide will help you choose the perfect blade so you can get clean, accurate cuts every time.
Here’s a quick overview of our top picks:
- Best Overall: Starrett Intenss Pro-Die Bandsaw Blade
- Best for Stainless Steel: Morse Metal Devil Bi-Metal Bandsaw Blade
- Best for Hard Metals: Milwaukee Hardcut Portable Bandsaw Blade
- Best Value: Timber Wolf Bandsaw Blade
- Best for Small Projects: Olson Saw FB63211DB Bandsaw Blade
Top 5 Best Bandsaw Blades For Metal
1. Starrett Intenss Pro-Die Bandsaw Blade
The Starrett Intenss Pro-Die is a workhorse. It’s designed for production cutting and tough alloys, which means it can handle just about anything you throw at it. I’ve used this blade on everything from mild steel to tool steel and it consistently delivers clean, accurate cuts.
Pros:
- ✅ Long blade life due to its unique tooth design
- ✅ Excellent for a wide range of metals
- ✅ Provides smooth and accurate cuts
Cons:
- ❌ Can be more expensive than other options
- ❌ May be overkill for very light-duty tasks
- ❌ Requires proper tensioning for optimal performance
Verdict: If you need a reliable, high-performance blade for demanding metal cutting, the Starrett Intenss Pro-Die is an excellent choice. It’s a solid investment if you use your bandsaw frequently.
2. Morse Metal Devil Bi-Metal Bandsaw Blade
Stainless steel can be a real pain to cut, but the Morse Metal Devil makes it much easier. This bi-metal blade is specifically designed to handle the unique challenges of stainless, resisting heat buildup and providing clean cuts. I remember struggling with a cheaper blade trying to cut some stainless tubing and it was a disaster, the Metal Devil made the job much easier.
Pros:
- ✅ Excellent for cutting stainless steel
- ✅ Bi-metal construction provides durability
- ✅ Resists heat buildup
Cons:
- ❌ May not be the best choice for softer metals
- ❌ Can be prone to chipping if used improperly
- ❌ Slightly more expensive than standard blades
Verdict: If you work with stainless steel regularly, the Morse Metal Devil is a must-have. It will save you time and frustration.
3. Milwaukee Hardcut Portable Bandsaw Blade
Portable bandsaws are incredibly handy for on-site work, and the Milwaukee Hardcut blade is designed to maximize their performance. This blade is tough and durable, able to withstand the rigors of portable use while still delivering clean cuts on a variety of metals. I’ve used this blade for cutting strut and pipe on job sites and it holds up incredibly well.
Pros:
- ✅ Durable construction for portable use
- ✅ Good for cutting a variety of metals
- ✅ Provides clean cuts in demanding conditions
Cons:
- ❌ May not be as precise as stationary bandsaw blades
- ❌ Can be more expensive than other portable options
- ❌ Shorter lifespan if used on extremely hard metals
Verdict: If you need a reliable blade for your portable bandsaw, the Milwaukee Hardcut is a great choice. It’s built to last and delivers consistent performance.
4. Timber Wolf Bandsaw Blade
The Timber Wolf bandsaw blade offers a great balance of performance and affordability. It’s a versatile blade that can handle a variety of metals, making it a good choice for hobbyists and DIYers. I’ve found it to be a good all-around blade for my home shop, especially for smaller projects.
Pros:
- ✅ Affordable price point
- ✅ Good for a variety of metals
- ✅ Smooth cutting action
Cons:
- ❌ May not be as durable as more expensive blades
- ❌ Not ideal for heavy production cutting
- ❌ Can require more frequent sharpening
Verdict: If you’re looking for a budget-friendly option that still performs well, the Timber Wolf bandsaw blade is a solid choice. It’s a great value for the price.
5. Olson Saw FB63211DB Bandsaw Blade
For intricate cuts and small projects, the Olson Saw FB63211DB is an excellent option. This blade is designed for precision, allowing you to make tight curves and detailed cuts in thin metals. I’ve used this blade for making small metal brackets and custom parts and it’s always performed well.
Pros:
- ✅ Excellent for intricate cuts
- ✅ Good for small projects
- ✅ Provides precise cuts
Cons:
- ❌ Not suitable for thick metals
- ❌ Can be fragile if used improperly
- ❌ Slower cutting speed compared to coarser blades
Verdict: If you need a blade for detailed metalwork, the Olson Saw FB63211DB is a great choice. It’s perfect for hobbyists and model makers.
Buying Guide
Choosing the right bandsaw blade for metal can seem daunting, but it doesn’t have to be. Here are a few key factors to consider:
- Material: What type of metal will you be cutting? Different blades are designed for different materials, such as steel, stainless steel, aluminum, and brass.
- TPI (Teeth Per Inch): The TPI determines the smoothness of the cut and the speed of cutting. Higher TPI blades are better for thin materials and intricate cuts, while lower TPI blades are better for thicker materials.
- Blade Material: Bi-metal blades are generally more durable and versatile than carbon steel blades. Carbide-tipped blades are the most durable and are ideal for cutting hard metals.
- Blade Length and Width: Make sure the blade length matches your bandsaw’s specifications. The blade width affects the minimum radius you can cut.
- Kerf: This is the width of the cut produced by the blade. A narrower kerf wastes less material.
Think about the type of metal you are cutting most often. If you cut a variety of materials, then a versatile blade is a great choice. If you are always cutting very hard metals, then a more specialized blade will be a better investment.
FAQs
Q: How often should I replace my bandsaw blade?
A: It depends on how often you use it and the type of metal you’re cutting. If you notice the blade is dull, not cutting straight, or producing rough cuts, it’s time to replace it.
Q: Can I use a wood-cutting bandsaw blade for metal?
A: No, wood-cutting blades have a different tooth geometry and are not designed to withstand the heat and friction of cutting metal. Using a wood-cutting blade on metal can damage the blade and be dangerous.
Q: What does TPI mean?
A: TPI stands for Teeth Per Inch. It refers to the number of teeth on the blade per inch of length. Higher TPI blades are better for thin materials and intricate cuts, while lower TPI blades are better for thicker materials.
Q: How important is bandsaw blade tension?
A: Proper blade tension is critical. Too little tension causes the blade to wander, resulting in inaccurate cuts. Too much tension can cause the blade to break. Refer to your bandsaw’s manual for the recommended tension.
Q: What is a bi-metal blade?
A: A bi-metal blade has a high-speed steel tooth edge welded to a flexible alloy steel back. This combination gives you the best of both worlds, a hard, wear-resistant cutting edge with a flexible, fatigue-resistant body.
Conclusion
Choosing the right bandsaw blade for metal makes all the difference. Whether you need a durable blade for your portable bandsaw or a precise blade for intricate cuts, there’s an option out there for you. Hopefully, this guide has helped you narrow down your choices and find the perfect blade for your needs. Happy cutting!
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