How to Cut Steel Sheet Metal

Before you begin the cutting process, you should consider the specifics of your project. Make a note of the metal you’re working with, the type of cuts you want to create, and the final application of your materials. These will influence the tools and methods you eventually choose.

The thickness of your metal – The thickness of the steel sheet metal you are cutting is an important factor. Make sure the tools you select are appropriate for the thickness of the metal to avoid damaging your materials or your equipment.

Type of cut required – You should next consider the types of cuts you need. For any given project, you might need straight cuts, curved cuts or complex shapes. The type of cut you need will affect the power tool you choose.

Power tools make cutting steel sheet metal faster and more efficient. There are several common power tools that you can choose – let’s look at each of them and what they’re best at:

Angle grinder – An angle grinder is a tool that excels at making quick straight cuts. Able to handle a variety of thicknesses, it is a great choice for cutting large sheets. While it is a great choice for straight cuts, note that it might not be the best pick for more complicated work.

Jigsaw – If you want to make more intricate cuts, including curves and shapes, a jigsaw is a strong choice. With an appropriate metal cutting disc attached, it can easily work through corners or complex patterns. It’s best suited for thin sheets of metal as thicker materials can wear out its blade quickly.

Plasma cutter – Looking to cut complicated designs? A plasma cutter works by using a high-velocity jet of ionised gas to effortlessly slice through metal. You’ll find plasma cutters in professional settings or used in more extensive projects.

Circular saw with metal-cutting blade – A circular saw equipped with a metal-cutting blade is ideal for making straight cuts and can also handle thicker metals when paired with the right blade. It offers a balance of speed and power, making it a great option for cutting through various metal thicknesses efficiently.

Cutting steel sheet metal can be dangerous if you don’t prioritise safety. Here are some key tips to keep in mind:

Protective equipment – Always gather suitable protective equipment before you begin. This includes eye protection, hearing protection, gloves and a respirator mask if necessary.

Workplace safety – You also need to safeguard your workspace. Make sure there is adequate ventilation and fire safety equipment on hand, and that all your tools have been regularly inspected.

Cut metal safety – When cuts have been made, you should always be careful of edges as these can be incredibly sharp. Always deburr and smooth out edges before handling the metal further. You should also make sure to properly store cut sheets to stop them from becoming a hazard.

Once you’ve chosen the appropriate tools for your project and have the right safety measures in place, it’s time to begin cutting. Begin by marking the cutting line on your steel sheet with a marker to ensure accuracy. Then, you should firmly secure the sheet to your workbench to prevent any movement during cutting.

When using your power tool of choice, maintain a steady hand to guide the tool along the marked line without forcing it. Remember to always let the tool do the hard work for you. Keep a close eye on the speed and pressure of your tool to prevent it from overheating.

Once your cut is complete, you should inspect the edges and use a file or grinder to smooth out any rough spots. This will not only improve the finish of your metal but will also remove any dangerous sharp edges.

If your project requires complicated shapes or difficult designs, you should adapt your approach to ensure precision and avoid damaging your metal. Here are some tips to keep in mind:

Templates and stencils – A good first step towards precision is to use templates and stencils. Trace your stencil onto your metal with a marker before cutting so that you know exactly where to guide your power tool.

Layered cutting – For particularly complex shapes, you can use layers to help with accuracy. Start with a rough cut, removing excess material, and then refine your shape with further cuts. This approach will help you to maintain control and precision and make the finer details easier to manage.

Post-cut finishing – After cutting a detailed design, you should take extra care to smooth out any issues. You should deburr edges to improve the appearance and safety of your final cut product.