Can You Cut Metal with a Jigsaw?
Yes — a jigsaw is one of the few power saws that can cut sheet metal, pipe, and steel effectively. However, metal cutting is completely different from wood cutting. You need the right blade, the right speed, and patience. Trying to rush metal cutting will snap blades, generate excessive heat, and produce poor results.
A jigsaw is particularly valuable for curved cuts in metal (pipes at an angle, shaped sheet metal blanks) and tight radius turns that would be difficult with other tools. With the right blade and technique, you can cut mild steel plate up to 6 mm thick, stainless steel, aluminium extrusion, and sheet metal down to 0.5 mm.
Why Metal Requires a Different Blade
Wood blades (HCS) are designed to shear through wood fibre. Metal is hard, dense, and doesn’t splinter — it deforms, tears, and generates intense heat. A wood blade will dull instantly or snap when forced through metal.
Metal cutting requires a BIM (bimetal) blade. The high-speed steel teeth stay sharp far longer, and the flexible steel backing resists breaking when the blade hits hard spots or tough material. Without bimetal, you’ll break blades constantly and produce rough, dangerous edges.
Blade Materials: HCS vs BIM for Metal
High Carbon Steel (HCS)
Never use HCS for metal. It will not work. HCS teeth are soft and will dull or break on the first attempt to cut steel or stainless. You’ll waste a blade, damage your jigsaw, and potentially create a dangerous situation (broken blade fragments).
Bimetal (BIM)
BIM is the only choice for metal. Bimetal blades have high-speed steel (HSS) teeth brazed onto a flexible spring-steel backing. HSS stays sharp through hard materials, and the backing flexes to absorb shock without breaking.
Every metal blade in your kit should be BIM. Look for “BIM” in the model name or description. If it doesn’t say bimetal, it’s not suitable for metal.
Cutting Different Metal Types
Thin Sheet Metal (Up to 1.5 mm) — Bosch T118A
| Specification | Detail |
|---|---|
| Model | Bosch T118A |
| Type | BIM (Bimetal) |
| TPI | 24 |
| Length | 60 mm |
| Shank | T-shank |
| Best For | Sheet metal, thin-wall tubing, roof flashing |
| Material Examples | Mild steel 0.u–1.5 mm, aluminium sheet, copper sheet |
| Recommended Speed | 1,500–2,000 SPM (slow) |
The T118A is a fine-tooth BIM blade specifically designed for thin materials. At 24 TPI, it has many teeth in contact with the thin metal, which prevents the blade from grabbing and deforming the material.
Thin sheet metal is delicate — if you push too hard or run the blade too fast, the teeth will catch and tear the material instead of cutting cleanly. Feed slowly and let the blade do the work.
Application examples:
- Cutting holes in sheet steel or stainless for plumbing access
- Trimming aluminium flashing or roof edging
- Cutting sheet metal blanks for light fabrication work
- Making shaped cuts in thin copper or brass sheet
Thick Steel Plate & Pipe (3–6 mm) — Bosch T118BF
| Specification | Detail |
|---|---|
| Model | Bosch T118BF |
| Type | BIM (Bimetal) |
| TPI | 18–21 (progressive tooth) |
| Length | 60 mm |
| Shank | T-shank |
| Best For | Thick steel plate, pipe cutting, angle iron |
| Material Examples | Mild steel 3–6 mm, steel tube 2–5 mm wall, pipe |
| Recommended Speed | 1,000–1,500 SPM (slow) |
The T118BF uses a progressive tooth pattern (alternating large and small teeth) to handle thicker steel. The larger teeth remove material quickly; the smaller teeth follow to clear chips and cool the blade. This pattern stays cooler and cuts more efficiently through tough material.
This is the blade for cutting steel tubing to length, angled cuts on pipe, and removing sections of steel plate. It’s slow work — expect to spend 2–3 minutes cutting through a 5 mm steel plate — but the progressive pattern ensures the cut stays clean and the blade doesn’t overheat.
Critical: Lubricate the blade with light machine oil (3-in-1 oil) during thick steel cuts. The friction generates intense heat, and oil cools the blade and prevents overheating. Apply oil to the cutting line every 30 seconds or so.
Application examples:
- Cutting 2–5 mm wall steel tube at an angle
- Removing sections of pipe for plumbing modifications
- Cutting mild steel plate for fabrication work
- Angled cuts on angle iron or flat bar
Aluminium (2–6 mm) — Bosch T127D
| Specification | Detail |
|---|---|
| Model | Bosch T127D |
| Type | BIM (Bimetal) |
| TPI | 14–18 |
| Length | 60 mm |
| Shank | T-shank |
| Best For | Aluminium extrusion, window frames, flat sheet |
| Recommended Speed | 1,500–2,000 SPM (medium) |
Aluminium is softer than steel but presents its own challenges. The major risk with aluminium is that the blade teeth will clog with shavings, causing the blade to gum up and stick. The T127D blade is designed to shed aluminium shavings efficiently and avoid clogging.
Aluminium also has a tendency to smear and deform if cut too slowly. Run the blade at a steady medium speed — not so fast that you overheat it, but fast enough that the shavings clear cleanly.
Lubrication tip: Some tradespeople apply a light spray of cutting fluid to aluminium to prevent gumming, but this isn’t essential for a jigsaw — just keep the speed steady and let the blade work.
Application examples:
- Cutting aluminium window frame sections
- Shaped cuts in aluminium composite panels (like roof lining)
- Trimming aluminium extrusion
- Removing sections of aluminium ducting or tubing
Stainless Steel (1–3 mm) — Bosch T118AO
| Specification | Detail |
|---|---|
| Model | Bosch T118AO |
| Type | BIM (Bimetal, heat-resistant) |
| TPI | 20–24 |
| Length | 60 mm |
| Shank | T-shank |
| Best For | Stainless steel sheet, tubing, specialist material |
| Recommended Speed | 500–1,000 SPM (very slow) |
Stainless steel is the hardest material you’ll cut with a jigsaw. The blade generates tremendous heat, and stainless is notorious for dulling blades quickly. However, the T118AO is a specialist heat-resistant BIM blade designed specifically for stainless. It’s more expensive than other BIM blades, but essential for stainless work.
Run very slowly (500–1,000 SPM if your jigsaw allows it). Feed incrementally and apply plenty of light machine oil. Expect the cut to take 5–10 minutes per 100 mm of stainless plate — it’s slow, but necessary for a clean result without breaking the blade.
Application examples:
- Cutting stainless steel kitchen bench cutouts
- Plumbing work with stainless tubing
- Fabrication work with stainless sheet
Copper & Brass (1–4 mm)
Copper and brass are softer than steel but very “sticky” — the blade tends to grab and jam. They cut cleanly with a fine BIM blade but require care to prevent the blade from stalling.
Best blade: Bosch T118A (24 TPI) for thin sheet, or Bosch T118BF (18–21 TPI) for thicker material. Feed slowly and steadily. Apply light machine oil to reduce friction and prevent the teeth from grabbing.
Cutting Technique for Metal
1. Clamp Your Workpiece Firmly
Metal is hard and can slip during cutting. Use a bench vise, clamps, or magnetic block to secure the material firmly. Never hold metal by hand near the blade — if the blade catches, it can snap and throw fragments.
2. Mark the Cutting Line Clearly
Use a permanent marker, soapstone, or metal scribe to mark the line. Metal’s hard surface makes it difficult to see pencil marks, especially on steel. Take time to mark accurately — metal cutting is slow, and a mistake means starting over.
3. Start at Low Speed
Begin the cut at the lowest speed setting on your jigsaw (500–1,000 SPM). This gives you control and prevents the blade from jamming as it enters the material. Once the blade is fully engaged (1–2 mm into the cut), you can increase speed slightly if needed.
4. Feed Slowly and Steadily
This is the most important rule: never force a metal cut. Push the jigsaw forward gently and let the blade do the work. Forcing causes the blade to overheat, dull quickly, and potentially snap. A good speed is 100–150 mm of forward progress per minute — yes, that slow.
5. Lubricate the Cut
For steel and stainless, apply light machine oil (3-in-1 oil, WD-40, or cutting fluid) to the cutting line every 30 seconds. Oil cools the blade and reduces friction, prolonging blade life and producing cleaner edges. Aluminium rarely needs lubrication but won’t hurt.
6. Listen to the Blade
If the blade starts to whine or scream, you’re going too fast or pushing too hard. Reduce speed and feed pressure immediately. The blade should make a steady, rhythmic cutting sound — if it sounds strained, back off.
Metal Blade Comparison Table
| Blade | Material | Thickness | TPI | Speed (SPM) | Best Use |
|---|---|---|---|---|---|
| Bosch T118A | Thin sheet, aluminium | <1.5 mm | 24 | 1,500–2,000 | Sheet metal, roofing, flashing |
| Bosch T118BF | Mild steel, pipe | 3–6 mm | 18–21 | 1,000–1,500 | Thick plate, tube, angle iron |
| Bosch T127D | Aluminium extrusion | 2–6 mm | 14–18 | 1,500–2,000 | Window frames, extrusion, composite |
| Bosch T118AO | Stainless steel | 1–3 mm | 20–24 | 500–1,000 | Stainless sheet, tubing |
Common Metal Cutting Problems
Blade Overheating or Discolouring
Problem: The blade turns blue or black during cutting.
Solution: You’re going too fast or pushing too hard. Reduce speed by half and feed more gently. Apply light machine oil to cool the blade. If the blade is already discoloured, it’s damaged — replace it.
Blade Stalling or Jamming
Problem: The blade gets stuck mid-cut.
Solution: Most common cause is debris buildup — swarf and metal shavings are jamming the blade. Stop, remove the workpiece, and manually clear any chips or swarf from around the blade. Restart slowly. If it happens repeatedly, switch to a different blade pattern (progressive instead of uniform) or use a coarser blade.
Rough, Torn Edges
Problem: The cut edge is jagged or deformed.
Solution: You’re pushing too fast. Reduce speed and feed pressure. Also verify you’re using the correct blade for the material — wrong blade = rough edge. Finally, check that your workpiece is clamped firmly — any vibration or flex will cause torn edges.
Recommended Metal Blade Set
A practical three-blade metal set covers most on-site metal cutting:
- Bosch T118A (24 TPI) — Sheet metal and thin tubes. This is your “default” metal blade.
- Bosch T118BF (18–21 TPI progressive) — Thick steel and pipe. Essential for serious metal work.
- Bosch T127D (14–18 TPI) — Aluminium extrusion and composite materials.
These three blades cover 90% of metal cutting work on a typical site. Add a T118AO if you regularly work with stainless steel.
Buy Bosch Metal Jigsaw Blade Sets on Amazon
Buy DeWalt Metal Jigsaw Blades on Amazon
Buy Milwaukee Metal Jigsaw Blades on Amazon
Safety When Cutting Metal
- Wear eye protection. Metal shavings and swarf can fly — always wear safety glasses.
- Wear gloves. The blade teeth and freshly cut metal edges are razor-sharp. Handle with care.
- Clamp your work. Never hold metal by hand near the blade. Use a vise or clamps.
- Check your blade. Before each cut, visually inspect the blade for cracks or damage. A broken blade can fragment.
- Watch for kickback. If the blade binds suddenly, the jigsaw can twist. Keep a firm grip and be ready to release the trigger.
- Let the blade cool. Between cuts, allow the blade to cool for 30 seconds. A hot blade is fragile.
Recommended Products
| Product | Details |
|---|---|
 |
Bosch T118A Metal Blade View on Amazon |
 |
DeWalt DT2294 10-Piece Set View on Amazon |
 |
Makita A-86898 Selection Pack View on Amazon |
Watch: Video Guide
Frequently Asked Questions
Can I use a wood blade to cut thin sheet metal?
No. Wood blades (HCS) will snap immediately on metal. You must use a BIM (bimetal) blade every time. There are no exceptions.
What’s the thickest metal I can cut with a jigsaw?
A standard jigsaw blade is 60 mm long, so theoretical maximum depth is around 25–30 mm (accounting for the baseplate and blade angle). In practice, you should not attempt to cut thicker than 6 mm mild steel or 3 mm stainless steel. Thicker cuts slow down dramatically and risk breaking the blade.
Should I use oil when cutting steel?
Yes, for thick steel (3+ mm) or stainless. Apply light machine oil (3-in-1, cutting fluid, or WD-40) to the cutting line every 30 seconds. Oil cools the blade and prevents overheating. For thin sheet metal, oil isn’t essential.
How slow should I feed the blade through metal?
Very slow. Aim for 100–150 mm of forward progress per minute. If the blade is whining or you feel resistance, slow down further. The jigsaw will tell you if you’re going too fast — listen to the sound.
What’s the difference between T118A and T118BF?
T118A has uniform 24 TPI and is designed for thin sheet metal (under 1.5 mm). T118BF has a progressive tooth pattern (18–21 TPI) for thick steel plate and pipe (3–6 mm). Use T118A for thin, T118BF for thick.
Can I cut stainless steel with a regular BIM blade?
You can try, but regular BIM blades will dull very quickly on stainless — you may get only 3–5 cuts before the blade is dull. The Bosch T118AO is heat-resistant and designed for stainless. If you cut stainless regularly, invest in T118AO blades.
