Key Criteria for Metal Cutting Bandsaw Blades

Blade material / tooth material

Hardness & toughness of the material being cut, plus wear resistance. You want something that can handle heat, abrasion, and metal hardness without failing early.

Teeth per inch (TPI) / pitch

Balances between how coarse the cut is, how smooth the surface finish is, and whether the blade can remove chips efficiently. Too many teeth for thick stock overload the gullets; too few for thin stock leave rough edges and vibration.

Blade width

Determines how tight curves you can cut (narrower blades better for curves), and how straight / stable the cut is on thicker, larger stock (wider blades resist deflection).

Blade thickness and back thickness

Affects blade stiffness (resisting twisting or bending), ability to handle tension, and compatibility with the saw's wheels / guides.

Tooth geometry / profile & set

Includes rake angle, tooth shape (hook, regular, skip, variable pitch), and how teeth are “set” (alternating offset / straight / wave). These influence chip removal, vibration, heat buildup, and finish.

Cut speed & feed (including coolant / lubrication)

Even with a good blade, wrong speed or feed will kill blade life or lead to poor cut quality. Metals often need slower speeds, more generous coolant, and proper feed.

Type of metal, hardness & shape

Is it mild steel? Stainless? Aluminum? Exotic alloys? Is the stock solid, tube/profile, or sheet? Thickness matters. What’s the hardness or heat treatment?

Saw capability & setup

The machine’s wheel size, power, tensioning ability, guide alignment, and whether it supports coolant or flood lubrication—all these limit what blades you can effectively use.

Carbon (or alloy) steel

Low cost; OK for soft non‑ferrous metals like aluminum, brass; occasional use

Will dull fast on harder metals; limited heat resistance; not ideal for heavy or hard duty.

Bi‑metal (High Speed Steel teeth welded to a flexible back)

Very versatile; good life; decent performance in many metals (mild steel, stainless, etc.); more forgiving in shop environments.

Higher cost than carbon; sensitive to overheating or abuse; may still struggle with very hard materials or very abrasive alloys.

Carbide‑tipped

Excellent for hard, abrasive, high heat metals; long life; can cut tough or exotic alloys well.

Expensive; more brittle (so fewer teeth in contact, careful feed, good supports needed); not always cost‑effective on soft metals; requires machine/rigid setup.

Mild Steel / Carbon Steel

< 1/8" (3 mm)

18–24 TPI

Bi-metal (M42)

Regular or variable pitch

150–250 SFM (45–75 m/min)

Use coolant for longer blade life

1/8"–1/2" (3–13 mm)

14–18 TPI

Bi-metal

Regular or hook

150–250 SFM (45–75 m/min)

Watch feed rate to prevent burning

1/2"–2" (13–50 mm) solid

6–10 TPI

Bi-metal

Hook tooth

100–200 SFM (30–60 m/min)

Slower speeds extend blade life

Tubing / profile

10–14 TPI

Bi-metal

Variable pitch

150–250 SFM (45–75 m/min)

Wave set reduces vibration

Stainless Steel (304, 316)

< 1/8" (3 mm)

20–24 TPI

Bi-metal (M42/M51)

Regular or variable pitch

70–150 SFM (20–45 m/min)

Always use coolant to avoid work-hardening

1/8"–1" (3–25 mm)

10–14 TPI

Bi-metal

Variable pitch

70–120 SFM (20–35 m/min)

Reduce cutting speed and feed pressure

>1" (25 mm) solid

4–6 TPI

Bi-metal or carbide

Hook or variable pitch

50–100 SFM (15–30 m/min)

Consider carbide for high-volume

Aluminum

Thin sheet / tubing

14–24 TPI

Bi-metal or carbon steel

Skip or hook

300–1,000 SFM (90–300 m/min)

Faster speeds OK, use wax

1/4"–1" (6–25 mm)

6–10 TPI

Bi-metal

Hook tooth

500–1,000 SFM (150–300 m/min)

Avoid clogging with sharp teeth

Solid bar / plate >1"

4–6 TPI

Bi-metal

Hook tooth

300–800 SFM (90–240 m/min)

Brush chips regularly

Tool Steel / Hardened Steel

Any

6–10 TPI

Carbide-tipped

Variable pitch, neutral rake

50–100 SFM (15–30 m/min)

Very slow feed, full coolant needed

Brass / Bronze / Copper

Thin / tubing

14–18 TPI

Bi-metal or carbon steel

Regular or skip

200–400 SFM (60–120 m/min)

Light lubricant helps

Solid bar

6–10 TPI

Bi-metal

Hook

150–300 SFM (45–90 m/min)

Soft but gummy – sharp blade essential

Cast Iron

Any

4–10 TPI

Bi-metal or carbide

Regular or skip

100–300 SFM (30–90 m/min)

Dry cut preferred; avoid coolant