The best metal-cutting band saw blade is the one that fits your saw and matches the material and shape you need to cut. Start with the machine’s required blade length, width and thickness; then choose a blade type and tooth pitch for solid stock, thin material, pipe, tube or structural profiles. No single blade or TPI is right for every project.
How to choose a metal-cutting band saw blade
- Check the saw’s requirements. Consult the machine manual for the required blade length, width and thickness, along with any limits on blade type or operation. A blade that does not fit the machine is not a candidate, regardless of its material rating.
- Identify the workpiece. Note the metal and, when available, its grade and hardness. Decide whether the cut is through solid stock, thin material, pipe, tube, a structural profile or a bundle. These shapes present different cutting demands.
- Choose pitch for the blade size and application. Compare the blade maker’s pitch options and application guidance for the dimensions that fit your saw. Do not select TPI from a universal rule: the appropriate pitch depends on both the workpiece and the blade dimensions.
- Match construction and duty to the job. A general-purpose M42 bi-metal blade may suit varied shop work; profiles and bundles have dedicated tooth geometries; and hard or difficult-to-machine metals may call for a heavy-duty blade intended for those materials.
- Set operating conditions from the machine and blade guidance. Use the makers’ material-specific recommendations for speed, feed, tension and cutting fluid. Treat chip appearance as a diagnostic clue, not a substitute for machine instructions or operator training.
On its Intenss and TENNAX-PRO product pages, Starrett advises users to locate the desired width and thickness before selecting pitch (TPI). See Starrett Intenss and Starrett TENNAX-PRO for manufacturer-listed options and applications.
Which blade type suits the work?
General-purpose maintenance and shop work
Starrett describes Intenss as an M42 bi-metal blade for horizontal and light-duty vertical machines. The maker lists applications including carbon steel and carbon-steel alloys, cast iron, copper alloys and aluminum, and offers multiple widths, thicknesses and pitches. That makes it a broad-purpose category to consider when the machine and cut match; it is not a universal winner, and the product description is manufacturer guidance rather than independent comparative testing.
Pipe, tube, profiles and bundles
Starrett describes TENNAX-PRO as a bi-metal blade with tooth geometry developed for pipes, tubes, structural profiles and bundles. Its product page also lists small solids and compatibility with manual, hydraulic and gravity-fed machines. Check the exact dimensions and pitch against the saw and cut rather than assuming every profile requires the same blade.
#1 Best Overall
- Bi-metal type, M42 grade, 93" long, 3/4" wide, 0.035" thick, 10-14 TPI
- Perfect for cutting soft ferrous metal
- 10/14tpi is suitable for cutting thin pipe tube profiles etc
- 10/14TPI is variable teeth, teeth size: 3 TPI > 3/4 TPI > 4/6 TPI > 5/8 TPI > 6/10 TPI > 8 TPI > 8/12 TPI > 10/14 TPI > 14 TPI
- Suits 7 x 12 bandsaw and all bandsaws which use 93" long, 3/4" wide bandsaw blade
Hard or difficult-to-machine metals
Starrett positions PRIMALLOY for heavy-duty work involving tool steel, high-speed steel, stainless steel, nickel and titanium alloys, and hardened steel. The maker says it uses a high-speed-steel edge alloyed with cobalt and vanadium and is intended for machines with hydraulic feed control. Consult the PRIMALLOY product guidance and the machine manual before choosing it.
What TPI should you use for metal?
There is no one TPI that suits all metal cuts. Blade makers offer different pitches for different blade dimensions and applications, and a pitch suited to one workpiece may not suit another. First narrow the choice to blades that fit the saw; then use the maker’s selection charts for the material and whether you are cutting solid stock, thin material or a profile. If the machine manual gives pitch guidance, follow it.
Rank #2
- 64-1/2" X 1/2" X 0.02" X 24 TPI Bi-Metal M42 Bandsaw Blade - 2 Pack
- 64.5 Inch bandsaw blades Compatible with WEN 3970, Grizzly G0622 , Harbor Freight, JET Model: HBS-56S (414301) 414458 HVBS-56M 414457 Horizontal/Vertical Band Saw POWERTEC , Shop Fox W1715 , SKIL, RIKON, Sears Craftsman, Compatible with BILT HARD 4"" x 6"" Metal-Cutting Band bandsaws requiring a 64-1/2" long 1/2" wide blade
- Recommended for cutting mild steel ,aluminum, angle iron, bronze, brass, copper, galvanized pipe, mild steel, and tougher steels including stainless, chrome, tungsten steel, plus other problem material at slow speed. However, it's also sharp and diverse enough to handle some hard plastics and all wood based projects.
- Perfect for soft metal, Wood, Stainless Steel, Aluminum, Brass, Plastic
- Fits all requiring a 64-1/2" long 1/2" wide Metal-Cutting Band Saw
For mixed work, choose based on the cuts you actually make and check the pitch guidance for each workpiece. A blade that suits a solid bar does not automatically suit a thin-walled tube or a bundle.
How material and hardness affect cutting settings
Blade choice alone does not determine a suitable cutting setup. Starrett’s Band Saw Blade Reference Guide lists speeds and cut rates by material grade and hardness, with values tied to stated workpiece conditions. For example, it lists AISI 1030–1055 and A36 at 175 HB with a recommended blade speed of 180–219 ft/min and a cut rate of 20–22 in²/min for the specified 2–5 inch workpiece dimension. For listed 316 stainless steel at 175 HB and the same dimension, it gives 68–78 ft/min and 3–5 in²/min. These are guide values, not universal settings for every saw or job. The accessed guide does not state a publication date. See Starrett’s Band Saw Blade Reference Guide.
Free tools Windows power users keep installed
One-click scans. No signup required.
Rank #3
- 59-1/2" X 1/2" X 0.025" X 18 TPI Bi-Metal M42 Bandsaw Blade
- 59.5 Inch bandsaw blades fit all requiring a 59-1/2" long 1/2" wide band saw
- Recommended for cutting mild steel ,aluminum, angle iron, bronze, brass, copper, galvanized pipe, mild steel, and tougher steels including stainless, chrome, tungsten steel, plus other problem material at slow speed. However, it's also sharp and diverse enough to handle some hard plastics and all wood based projects.
- Perfect for soft metal, Wood, Stainless Steel, Aluminum, Brass, Plastic
- Bi-Metal HSS M42 grade, 8% Cobalt Content For Added Durability & Wear
Use chip appearance to troubleshoot cautiously
Starrett’s reference guide offers chip appearance as a clue when evaluating a cut. Powdered silver chips point to reducing blade speed and increasing feed; thick, short blue or brown chips suggest reducing both speed and feed and checking cutting fluid. These are the guide’s suggestions, not a diagnosis that fits every machine or material. Check the saw and blade makers’ procedures before changing settings.
The guide also warns that insufficient blade tension can reduce cutting efficiency, while excessive tension may break the blade. Use the machine maker’s procedure to set tension; do not guess or compensate for a poor cut by overtightening.
Rank #4
- Bandsaw Blade 64-1/2" X 1/2" X 0.02" X 18 TPI Metal Cutting Bi-Metal M42 8% Cobalt - 2 Pack
- 64.5 Inch bandsaw blades Compatible with WEN 3970, Grizzly G0622 G9742 , Harbor Freight, JET Model: HBS-56S (414301) 414458 HVBS-56M 414457 Horizontal/Vertical Band Saw POWERTEC , Shop Fox W1715 , SKIL, RIKON, Sears Craftsman, Compatible with BILT HARD 4"" x 6"" Metal-Cutting Band bandsaws requiring a 64-1/2" long 1/2" wide blade
- Recommended for cutting mild steel ,aluminum, angle iron, bronze, brass, copper, galvanized pipe, mild steel, and tougher steels including stainless, chrome, tungsten steel, plus other problem material at slow speed. However, it's also sharp and diverse enough to handle some hard plastics and all wood based projects.
- Fits Most 6" x 4 " band saws and all requiring a 64-1/2" long 1/2" wide Band Saw
- Bi-Metal HSS M42 grade, 8% Cobalt Content For Added Durability & Wear
What to confirm before buying
- The saw’s required blade length, width and thickness, as specified in its manual.
- The workpiece material and, where known, grade and hardness.
- Whether the cut is through solid stock, thin material, pipe, tube, a structural profile or a bundle.
- The blade maker’s available pitches for the compatible dimensions and intended application.
- Any machine requirements for blade type, feed control, speed, tension and cutting fluid.
Without the saw model and workpiece details, it is not possible to identify one best SKU or TPI for every reader. Manufacturer product descriptions and operating tables are useful selection guidance, but they do not establish comparative rankings for blade life, speed, precision or value.
Quick Recap
Best Value
- 93-Inch x 3/4" X 0.035 X 5/8 TPI Band saw Blade for Metal Cutting
- Perfect for Stainless Steel, Aluminum, Brass, Plastic, Soft metal, Wood
- Fits all band saws requiring a 93" long 3/4" wide blade
- 8% cobalt with 2% tungsten content to increase durability abrasive resistance
- Rc 66-68 Tooth Hardness For Increased Wear Resistance
Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.
What’s actually slowing this PC down?
Pick the symptom - the matching free tool is one click away.
