Metal Cutting Saws Compared by Cut Capacity and Power
Milwaukee 6238-21 deep cut band saw leads for portable steel cutting, thanks to its wide cut capacity and variable speed. DEWALT DWM120K offers similar capability at a lower cost, and WEN 3970 chop saw suits shops needing a stationary budget option for pipe and angle iron work.
Milwaukee 6238-21 handles steel pipe and angle iron cleanly thanks to its deep cut capacity, though its weight makes overhead cuts tiring.
Chop saws, band saws, and circular saws each suit different metal shapes. We compared cut depth, motor power, and blade type against owner reports of blade life.
The shortlist, ranked
Milwaukee 6238-21 Deep Cut Portable Band Saw
A 5 inch round or rectangular workpiece fits through this band saw in a single pass, more than most portable saws in its class. Variable-speed trigger control shifts blade speed between thin-wall conduit and solid bar stock. Metal housing survives daily drops and dust on a job site.
Pros
- Deep cut capacity handles large stock in one pass
- Variable speed suits multiple metal types
- Metal housing holds up under daily job site use
Cons
- Heavier than compact band saws at 12.8 lbs
- Blade changes take longer than tool-free designs
DEWALT DWM120K Portable Band Saw
A 5 inch round cut capacity matches pricier band saws, while a lower 10 amp draw keeps the tool lighter in hand. Tool-free blade changes speed up repeated cuts on a job site. A built-in LED work light helps in dim shop corners.
Pros
- Tool-free blade changes save setup time
- Built-in LED work light aids dim workspaces
- Lighter than the Milwaukee 6238-21 at 10.3 lbs
Cons
- Fixed 340 SFPM blade speed limits material range
- Lower amp motor slows cuts through thick stock
WEN 3970 14-Inch Metal-Cutting Chop Saw
A stationary 15 amp motor drives a 14 inch abrasive wheel through angle iron and rebar at a low price. A spark guard and clamping vise keep the workpiece steady during repeated shop cuts. Portability trails band saws, since the 42 lb base stays bench-mounted.
Pros
- Low price for a stationary metal saw
- Clamping vise steadies the workpiece
- Spark guard improves shop safety
Cons
- Not portable for job site work
- Abrasive wheels wear faster than toothed blades
Evolution Power Tools S355CPSL Steel Cutting Chop Saw
A cold-cut TCT blade replaces the abrasive wheel, cutting steel without sparks or the burrs typical of friction saws. Cooler cuts extend blade life on thick angle iron. Extra blade weight adds heft compared with chop saws built around abrasive wheels.
Pros
- No sparks or burrs on cut edges
- Blade life outlasts abrasive wheels
- Cleaner finish cuts down on deburring time
Cons
- Heavier than standard abrasive chop saws
- Replacement cold-cut blades cost more upfront
Makita LC1230 12-Inch Metal Cutting Saw
A 15 amp motor spins a 12 inch carbide blade at 1,300 RPM for cleaner cuts on aluminum extrusion and thin steel than abrasive wheels leave. Lighter blade mass also cuts vibration during repeated cuts. Cut capacity trails 14 inch chop saws on thicker material.
Pros
- Clean, low-burr cut finish on aluminum and steel
- Less vibration than abrasive wheel saws
- Carbide blade suits thin stock precision work
Cons
- Smaller 3.9 in cut capacity than 14 in saws
- Carbide blades cost more than abrasive wheels
Milwaukee 6270-21 Metal Cutting Circular Saw
This handheld saw cuts studs, angle iron, and sheet metal on site without hauling a stationary chop saw. A 6 inch carbide blade spins at a lower RPM tuned for metal instead of wood. Cut depth of 2.06 inches suits thin stock more than solid bar.
Pros
- Handheld design suits on-site cutting
- Lighter than band or chop saws at 8.4 lbs
- Handles sheet metal and stud cuts well
Cons
- Shallower cut depth than band saws
- Not built for thick round stock
DEWALT DW872 14-Inch Multi-Tap Chop Saw
A quick-release vise and multi-tap angle adjustment let shop workers switch cut angles fast during production runs. The 15 amp motor pushes through steel pipe and solid bar without bogging down. A stationary base needs bench space that portable saws avoid.
Pros
- Multi-tap adjustment speeds up angle changes
- Handles repeated production cuts without bogging
- Quick-release vise cuts setup time between parts
Cons
- Requires dedicated bench space at 44 lbs
- Abrasive wheels need frequent replacement
What to look for
What to look for Cut capacity decides whether a saw handles solid bar stock or only thin pipe and sheet metal. Portable band saws generally cut deeper relative to their size than compact circular saws do. Motor amperage affects how well a saw pushes through thick steel without stalling. Most saws in this category run between 10 and 15 amps.
Choosing between blade types Abrasive wheels cut fast and cost less upfront, but they wear down quickly and throw sparks. Carbide-tipped and cold-cut blades last longer and leave cleaner edges, cutting down on deburring afterward. Shops cutting steel daily often save money over time despite the higher blade cost. Cold-cut blades also run cooler, extending life on thick angle iron.
Best for job site portability Handheld circular saws and portable band saws travel easily in a truck bed or tool bag. Corded models skip battery weight but need access to power on site. Weight matters more here than in a stationary shop saw, since crews carry and reposition the tool all day. A saw under 13 lbs stays manageable for overhead cuts.
Best for high-volume production Stationary chop saws with quick-release vises and multi-tap angle adjustments speed up repeated cuts on identical parts. A dedicated bench location makes sense once cutting volume justifies giving up portability. Spark guards and clamping systems matter more here, since operators run the saw for full shifts. Abrasive wheel replacement becomes a routine cost at this pace.
Side by side
| # | Model | Cut capacity | Best for | Score | Price |
|---|---|---|---|---|---|
| 1 | Milwaukee 6238-21 Deep Cut Portable Band Saw | 5 in round, 5×5 in rectangular | Best overall | 9.4 | Check price |
| 2 | DEWALT DWM120K Portable Band Saw | 5 in round | Best value | 9.0 | Check price |
| 3 | WEN 3970 14-Inch Metal-Cutting Chop Saw | 14 in abrasive wheel | Best budget | 8.0 | Check price |
| 4 | Evolution Power Tools S355CPSL Steel Cutting Chop Saw | 14 in cold-cut TCT | Best for heavy steel | 8.8 | Check price |
| 5 | Makita LC1230 12-Inch Metal Cutting Saw | 12 in carbide-tipped | Best for clean cuts | 8.5 | Check price |
| 6 | Milwaukee 6270-21 Metal Cutting Circular Saw | 6 in carbide-tipped | Best for portability | 8.3 | Check price |
| 7 | DEWALT DW872 14-Inch Multi-Tap Chop Saw | 14 in abrasive wheel | Best for high-volume shop use | 8.6 | Check price |
Good to know
What is the best saw for cutting metal pipe?
A portable band saw like the Milwaukee 6238-21 handles round pipe cleanly with its deep cut capacity and variable blade speed.
Can a circular saw cut metal?
Yes, with a carbide-tipped blade rated for steel or aluminum. Standard wood blades are not safe for metal cutting.
Chop saw vs band saw, which cuts metal better?
Chop saws cut faster on thick, straight stock. Band saws leave a cleaner cut with less heat and handle irregular shapes better.
Do metal cutting saws need special blades?
Yes. Blades match the material and saw type, ranging from abrasive wheels to carbide-tipped and cold-cut blades.
Is a cold-cut saw better than an abrasive chop saw?
Cold-cut saws produce less heat, fewer sparks, and cleaner edges, though replacement blades cost more than abrasive wheels.
What size saw do I need for angle iron?
A 14 inch chop saw or a band saw with at least 4 inch round capacity handles most standard angle iron sizes.
Are portable band saws good for beginners?
Yes. Variable-speed models like the DEWALT DWM120K stay forgiving across different metals and easier to control than handheld circular saws.
How often do metal cutting blades need replacing?
Abrasive wheels wear out after several dozen cuts on thick steel. Carbide-tipped and cold-cut blades can last hundreds of cuts with proper use.
Which metal cutting saw suits heavy steel best?
The Evolution S355CPSL cold-cut chop saw handles thick angle iron with less heat and fewer burrs than abrasive wheel saws.
Our pick
Milwaukee 6238-21 earns the top recommendation for its deep cut capacity and variable speed control across pipe and bar stock. Budget-focused buyers should choose the WEN 3970 chop saw instead, and shops cutting steel daily get better long-term value from the cold-cut blade on the Evolution S355CPSL.
