How to Cut Sheet Metal by Hand or with Power Tools

Cutting sheet metal is a necessary and common operation for the construction or repair of certain structures. Just like drilling metal. Sheet metal is cut in hydraulics, in construction, in automotive and aerospace mechanics.

There is also a lot of work in this field in emergency medicine, for example during car accidents firefighters must cut thick and steel-containing sheet metal quickly. But this need to cut iron is a special eventuality.

In most cases we can work comfortably and calmly. There remains one point: we don't always have in front of us an aluminum sheet but in many circumstances we must proceed with cutting a thick sheet metal. How do we proceed with hard metal? Here are the main tools and techniques to shape a sheet metal as best as possible in the workshop.

Scissors

The first method for cutting sheet metal at any time: you can use shears specific to this work. We're talking about minimal thicknesses although everything depends on the model. Some shears can cut very thin sheet metal and are used with one hand, they are very similar to common scissors. Others, however, can guarantee better results.

This thanks to a series of details: lever system to reduce effort, longer and more ergonomic handles, curved blade to cut sheet metal in depth without problems. These shears (here is a valid model) are perfect for quick interventions.

There is an electric version of the sheet metal shears: it's a tool with a body similar to an angle grinder but with a head that has a space in which to insert the metal profile. Once the power tool is started, it cuts quickly, without hesitation.

Jigsaw

A method of cutting sheet metal that you can also use at home or in your personal workshop. It is a solution suitable for small work or for making shapes with specific forms. For example, if you want to cut a sheet metal by performing a curve or a hole with large diameter you can do it easily. It is not ideal for cutting a corrugated sheet metal because its use involves resting the slide on the smooth surface. For corrugated cutting it's better to use shears which are more versatile.

Shear machine

Another useful tool for precisely cutting sheet metal. The shear machine is a specific tool for this task, suitable for those who work daily in the sector. It is used in the areas of sheet metal work (craft metal sheet working) and carpentry, is found in blacksmith shops and is used to create precise cuts on metal sheets of different types.

In this case we have manual and electric solutions, but for demanding activities there are pneumatic options. The operation is simple but effective: a blade or punch is used to perform an alternating movement, and cut the necessary material. The substantial advantages of the shear machine: you can cut sheet metal without bending or deforming it, with edge precision.

Saws and angle grinders

Excellent solutions for cutting thicker sheet metal, those made of steel that cannot be treated with manual methods. Let's start with the classic angle grinder with discs for cutting iron that you can use for thicker sheet metal.

In the same way, you can use this tool with discs for cutting building materials or for grinding the weld bead. Another very valuable tool for modifying large sheet metal is the circular saw with specific disc for metals.

Guillotine

While shears and shear machines (electric or manual) are tools capable of cutting sheet metal in detail, creating curves and shapes, guillotines serve to cut large metal sheets - even stainless steel - with precision and execution speed. There are bench versions for smaller work and hydraulic machines for industrial or anyway specialized workshop activities.

This tool is inserted in the professional methods of sheet metal processing and among these we have plasma cutting - a nozzle that blows gas at high speed that passes through an electric arc - water cutting and with laser: solutions suitable not only for cutting but also for decorating and engraving shapes or letters on sheet metal that we want to personalize.