What are some common uses for a hole saw for cutting thick metal?

Mike Fleming

Different Brands and Types of Hole Saws for Cutting Thick Metal

Different brands and types of hole saws are available on the market today, each with its own unique set of features and benefits. Choosing the right hole saw for your needs is essential when cutting thick metal, so here is a closer look at some of the most popular options.

BEST FOR THICK METAL: DEWALT DCS391X1 10-Inch Max Capacity Hole Saw

The Dewalt DCS391X1 10-Inch Max Capacity Hole Saw is ideal for cutting through thick metal plates or sheets. It has a max capacity of 10 inches, which means it can handle larger pieces with ease. The saw also has a spiral blade design that cuts through metal more easily than other types of saws. Additionally, the saw has a built-in guard rail that helps keep your hands safe while you work.

BEST FOR LEGITIMATE CUTTING: Makita LXT204 12-Inch Max Capacity Benchtop Hole Saw

The Makita LXT204 12-Inch Max Capacity Benchtop Hole Saw is perfect for people who want to cut through thicker metal sheets with confidence. It has a max capacity of 12 inches and features an adjustable fence that allows you to create accurate cuts. Additionally, the saw has a built-in chip ejector system that quickly removes chips from your blade so you can focus on cutting without interruption. Finally, the LXT204 comes with a 2-year warranty to ensure you are fully protected if anything goes wrong during use.



A hole saw is a versatile tool for cutting through thick metal. It has a sharp blade that makes it easy to cut through steel, aluminum, and other metals. Hole saws are also convenient because they have a long handle that allows you to reach tight spaces.

The Different Types of Hole Saws

There are three main types of hole saws that can be used for cutting thick metal: the circular saw, the jigsaw, and the band saw. Each type has its own advantages and disadvantages when it comes to cutting thick metal.

Circular Saw: The circular saw is the most common type of hole saw, and it is usually best for cutting small pieces of metal. The circular saw has a blade that spins around a central hub, making it easy to cut through thick metal. However, the circular saw is not very powerful, and it can be difficult to handle when cutting large pieces of metal.

Jigsaw: The jigsaw is similar to the circular saw in that it has a rotating blade. However, the jigsaw is much more powerful than the circular saw, and it is also easier to handle because it has a built-in stand. This makes it ideal for larger pieces of metal that cannot be easily cut with a circular saw or a band saw.

Band Saw: The band saw is unique because it does not have a blade; instead, it has bands that slice through metal. This makes the band Saw perfect for cutting thick pieces of metal because it does not require as much power as other types of hole saws do.

How to Use a Hole Saw

Hole saws are used for precision cutting of thick metal. When using a hole saw, it is important to follow the safety guidelines that come with the tool. First, make sure the hole saw is properly sharpened before use. Second, use caution when drilling into hard materials as the hole saw can create potentially dangerous sparks. Finally, always wear eye and ear protection when using a hole saw.

How to Safely Cut Thick Metal with a Hole Saw

There are a few things you need to take into account when cutting thick metal with a hole saw. First, always use a safety guard! Second, make sure the blade is sharp and the hole saw is properly adjusted. Third, make sure the metal is flat against the table or work surface. Finally, be patient - it can take some time to cut through thick metal.


There is no doubt that a hole saw is an incredibly versatile tool for cutting through thick metal. Its relatively small size and ability to quickly make precise cuts makes it an excellent choice for many applications. While a hole saw can be used to cut a variety of materials, its ­primary use is in cutting through heavy steel or other metals.

A hole saw’s ability to quickly and easily cut through thick metal is one of its most important features. This is because thick metal offers little resistance to the blade, making it easy for the hole saw to make precise cuts. Additionally, the small size of the hole saw makes it easy to maneuver around difficult-to-reach areas.

While a hole saw does have its limitations, these are mainly related to its size and speed. For example, a hole saw cannot handle very high levels of stress or torque, which can cause it to break or fail prematurely. Additionally, while a hole saw can easily cut through metal, it cannot do so with accuracy if the material is too thin or too soft.

Overall, a hole saw is an incredibly versatile tool that can be used for a variety of applications in the construction or manufacturing industry. Its small size and quickness make it an ideal choice for accessing difficult-to-reach areas, while its ability to make precise cuts through heavy metal makes it an especially valuable tool in this regard.


Mike Fleming

Mike Fleming is an expert in industrial engineering and a recent graduate of Dartmouth. He now lives in Boston with his wife and 1 child. In his free time, he enjoys running and hiking. Mike has worked as an engineer for over 10 years, and has experience in a variety of industries.