If you frequently work with metal, choosing the right sawzall blade can make or break your project. You might be wondering which blades offer the perfect combination of precision, durability, and speed. That’s exactly what we’ll cover today.
First, let’s address the types of tools that complement these blades. For heavy-duty projects, best steel cut off saws can save time and effort. On the other hand, if you already own a reciprocating saw, pairing it with the best sawzall blades for cutting thick metal ensures smooth and accurate cuts. And for versatile metalwork, a best metal cutting saw can handle everything from mild steel to hardened alloys.
But don’t worry—we’ll break it down step by step, covering the best blades, how to use them, and tips to get flawless results every time. Keep reading to find the ultimate guide for cutting steel efficiently.
Top Picks
Best for Metal Cutting: MILWAUKEE Tri-Lingual Super SAWZALL Blade 14T 9in Length TORCH
Milwaukee’s 9-inch bi-metal reciprocating saw blade delivers consistent performance for professionals who frequently cut through medium-gauge metals. With 14 teeth per inch, it strikes a balance between speed and precision, producing smooth cuts across materials like conduit, tubing, and pipe. The bi-metal construction enhances durability, allowing the blades to resist wear and heat buildup during prolonged use. Its 1/2-inch universal tang design ensures compatibility with all Sawzall models, making it versatile for most metalworking tasks.
From a customer perspective, users appreciate the reliability and consistent sharpness of the Milwaukee blades, noting they stay effective even after repeated use on dense metals. Contractors often highlight the convenience of the 25-blade pack, which offers long-term value and minimizes downtime on job sites. Some users, however, mention that the full pack adds a bit of bulk when stored in smaller toolboxes. Overall, it’s a trusted choice for those needing industrial-grade performance and longevity in demanding environments.
Best for Ultra-Hard Metals: 3 Pack 6 inch 8 TPI Diablo Steel Demon Amped Carbide Reciprocating Saw Blades
The Diablo Steel Demon Amped blades from Brock are engineered for cutting the toughest materials, including boron steel, UHSS, stainless steel, and cast iron. Each 6-inch blade features an 8 TPI configuration that balances aggressive cutting power with stability, making it ideal for thick metals ranging from 3/16 to 9/16 inches. The combination of alloy steel, carbide, and stainless construction enhances both strength and longevity, allowing the blades to endure high friction and temperature without dulling quickly.
From the user perspective, these blades are praised for their ability to slice through hardened and high-strength metals where standard bi-metal blades fail. Professionals in automotive repair and demolition often note the clean, steady cuts and reduced vibration, which help maintain precision and control during use. However, some users find the 6-inch length slightly restrictive for deeper cuts, especially in large pipes or beams. Overall, this 3-pack set is valued for its exceptional endurance and cutting efficiency in demanding metalworking applications.
Best for Auto Dismantling: 25 Pack 9 inch 14/18 TPI Diablo Steel Demon Bi-Metal Auto Dismantling Reciprocating Saw Blades
The Brock 9-inch Diablo Steel Demon bi-metal reciprocating saw blades are designed for professionals in automotive dismantling and metal fabrication. Featuring a variable 14/18 TPI tooth configuration, these blades offer excellent versatility—providing fast cuts in thinner materials while maintaining control and smoothness in medium-gauge metals between 1/16 and 5/16 inches thick. The bi-metal design combines flexibility and heat resistance, ensuring that the blades resist bending and breakage even under heavy workloads.
From a customer standpoint, users appreciate the consistent performance and durability across multiple cuts, especially when working with auto body panels, exhaust tubing, and light structural steel. The 9-inch length adds extra reach, making it easier to cut in tight or obstructed areas during dismantling jobs. Many buyers also value the 25-pack bundle for its cost efficiency and convenience in professional workshops. However, some users note that these blades perform best with medium metals and can wear faster when used on thicker or hardened steel. Overall, it’s a dependable, workshop-grade solution for metal and automotive cutting applications.
FAQs
What is the best sawzall blade for steel?
When it comes to cutting steel, not all sawzall blades are created equal. The best sawzall blades for steel are typically made from high-speed steel (HSS) or bi-metal construction. These blades combine flexibility with toughness, preventing breakage while maintaining sharpness over repeated cuts.
Look for blades labeled specifically for metal cutting. A blade with 18–24 teeth per inch (TPI) is ideal for thin steel sheets, while 14–18 TPI works better for thicker steel pipes or beams. The combination of the right TPI and bi-metal durability ensures clean cuts without overheating the blade or damaging the material.
What is the best blade to cut steel with?
If your goal is precision and longevity, bi-metal blades are the top choice. They feature hardened teeth welded to a flexible steel body, allowing you to cut through both soft and hard steels. For everyday steel cutting, opt for blades designed for general-purpose metalwork.
For thicker materials, consider blades with higher TPI for smoother finishes. Additionally, cobalt-infused blades are excellent for cutting alloyed or hardened steels, providing longer life and reducing the need for frequent blade changes. Remember, pairing the blade with a saw that delivers consistent speed and stability will make your work safer and more efficient.
What sawzall blade cuts hardened steel?
Cutting hardened steel is more challenging due to its toughness. The ideal sawzall blade is made from cobalt or high-speed steel (HSS), often labeled “bi-metal” for maximum strength. These blades resist heat buildup, maintain sharp teeth, and prevent chipping when cutting hardened surfaces.
Additionally, using a slower cutting speed and steady pressure can extend blade life. Blades with a TPI range of 14–18 are usually most effective, though specialized carbide-tipped blades can handle extremely hardened steels if precision is required.
How thick of steel will a sawzall cut?
A reciprocating saw can typically cut steel up to 3/8 inch thick with standard bi-metal blades. With heavy-duty blades or industrial-grade sawzalls, thicknesses up to 1/2 inch or more are possible.
Keep in mind that blade length also affects capacity. Longer blades allow deeper cuts and better reach in tight spaces. For very thick steel, consider multiple passes instead of forcing a single cut, which can overheat and wear out the blade prematurely. Always pair the blade with proper support and clamp the material securely to avoid vibration and uneven cuts.
Final Thoughts
Selecting the right sawzall blade for steel is critical for efficiency, safety, and precision. Bi-metal and cobalt blades dominate for their strength and durability, while TPI and blade length ensure smooth cuts across different steel thicknesses. By understanding blade materials, tooth design, and appropriate saw pairing, you can handle everything from thin sheets to hardened steel with confidence. Invest in the best blades, and your steel cutting projects will be faster, cleaner, and far less frustrating.
