What’s the Best Way to Cut Metal?

Cutting metal is a crucial process in many industries, from construction to aerospace. It involves the separation of metal sheets, rods, or tubes into smaller pieces, according to specific measurements and shapes. There are various methods of cutting metal, and choosing the right one depends on several factors, such as the metal’s thickness, hardness, and type, as well as the desired accuracy, speed, and cost-effectiveness. In this article, we will explore the different ways of cutting metal and discuss the best approach for different scenarios.

  1. Manual cutting

The most basic method of cutting metal is by hand, using tools such as hacksaws, tin snips, or metal shears including hand held shears and table top or floor mounted shears. This approach is suitable for thin sheets or soft metals such as aluminum or copper, where precision is not critical. Hand cutting can be time-consuming and tiring, especially for thicker or harder metals, and may result in jagged edges or inconsistent shapes. For thicker sheet metal, a stand alone shear will provide the best cut. Therefore, it is not recommended for industrial or large-scale projects but can be useful for small repairs or DIY tasks.

  1. Abrasive cutting

Abrasive cutting involves the use of a high-speed rotating disc or wheel, which grinds away the metal surface to create a cut. This method is efficient for cutting thicker metals, such as steel or titanium, and can achieve precise shapes and sizes. However, abrasive cutting generates a lot of heat and sparks, which can cause deformation or damage to the metal, as well as safety hazards for the operator. Additionally, abrasive cutting discs wear out quickly and require frequent replacement, adding to the cost and maintenance of the equipment.

  1. Thermal cutting

Thermal cutting utilizes heat to melt or vaporize the metal, creating a clean and smooth cut. There are two main types of thermal cutting: flame cutting and plasma cutting.

Flame cutting involves the use of a torch that burns a mixture of fuel gas and oxygen, producing a high-temperature flame that melts the metal surface. The melted metal is then blown away by a jet of oxygen, creating a cut. Flame cutting is suitable for thick and tough metals, such as steel or cast iron, and can cut through rust or paint. However, flame cutting generates a lot of heat and can cause warping or distortion of the metal, as well as creating toxic fumes and fire hazards.

Plasma cutting uses an electric arc to ionize gas and create a high-velocity plasma stream that melts the metal and blows it away. Plasma cutting is faster and more precise than flame cutting, and can cut through thicker metals, such as stainless steel or aluminum. Plasma cutting produces less heat and minimal distortion, making it suitable for intricate designs and high-precision applications. However, plasma cutting requires specialized equipment and can be expensive, especially for larger or thicker metals.

  1. Laser cutting

Laser cutting is a non-contact method of cutting metal, using a high-powered laser beam to melt or vaporize the metal along a predetermined path. Laser cutting is highly accurate and can create complex shapes and patterns with minimal distortion or waste. Laser cutting is suitable for thin and medium thickness metals, such as stainless steel or brass, and can achieve high production rates. However, laser cutting requires a significant initial investment in the equipment and maintenance, as well as skilled operators and safety precautions.

  1. Waterjet cutting

Waterjet cutting utilizes a high-pressure jet of water mixed with abrasive particles, such as garnet, to cut through the metal surface. Waterjet cutting is versatile and can cut through a wide range of materials, including metals, ceramics, plastics, and composites, without generating heat or fumes. Waterjet cutting is suitable for thin to thick metals, depending on the water pressure and the size of the abrasive particles. Waterjet cutting produces a smooth and clean cut, without warping or distortion, and minimal material waste. However, waterjet cutting can be slower than other methods, and the abrasive particles can cause wear and tear on the equipment and require frequent replacement.

Factors to Consider

Choosing the best method for cutting metal depends on several factors, such as:

  1. Metal type: Different metals have different properties, such as thickness, hardness, conductivity, and chemical composition, which can affect the cutting process. For example, a soft metal like aluminum may be cut by hand or abrasive cutting, while a hard metal like titanium may require plasma cutting or laser cutting.
  2. Metal thickness: The thickness of the metal sheet or plate is a crucial factor in determining the appropriate cutting method. Thinner metals can be cut by hand or waterjet cutting, while thicker metals may require flame cutting or plasma cutting.
  3. Cutting accuracy: The level of precision required for the cut depends on the intended use of the metal pieces. For example, aerospace or medical applications may require high accuracy and minimal distortion, while construction or fabrication may allow for some tolerance.
  4. Cutting speed: The production rate and turnaround time for the cut also affect the choice of cutting method. Faster methods such as plasma cutting or waterjet cutting may be suitable for high-volume projects, while slower methods such as hand cutting or laser cutting may be more appropriate for low-volume or custom designs.
  5. Cost-effectiveness: The cost of the cutting method, including equipment, maintenance, and labor, also plays a role in determining the overall efficiency of the process. Some methods may require a higher initial investment but offer lower operational costs, while others may be cheaper upfront but require more frequent replacements or maintenance.


Cutting metal is a critical process that requires careful consideration of the metal properties, cutting methods, and production requirements. Depending on the metal type, thickness, accuracy, speed, and cost-effectiveness, various methods can be used, such as manual cutting, abrasive cutting, thermal cutting, laser cutting, and waterjet cutting. Each method has its advantages and disadvantages, and the choice of the best method depends on the specific application and project requirements.

Ultimately, it is essential to work with experienced professionals and reliable equipment to ensure the highest quality and safety of the metal cutting process. Proper training, maintenance, and safety precautions can minimize risks and ensure efficient and precise results.