What is a metal band saw and how does it work?
A metal band saw is a machine tool in which a closed, ring-shaped band serves as the cutting tool . This runs continuously over two driven rollers and is precisely aligned with the workpiece by ball-bearing guides. The result: smooth, clean cuts with minimal burr – even in hard solid material, thick-walled tubes or demanding alloys such as stainless steel.
Unlike circular saws or cut-off grinders, band saws operate slowly and in a controlled manner. This protects the material, extends the service life of the band and ensures repeatable accuracy – even in long production runs. The variable cutting speed allows for precise adjustment to the specific material, as soft non-ferrous metals such as aluminium or copper require different settings to hard steels or high-alloy grades.
Designs: horizontal, vertical or combination?
Metal band saws are available in several designs – and choosing the right configuration is often more important than the brand. Horizontal, vertical and combined machines differ fundamentally in their cutting action and thus in their areas of application.
Horizontal metal band saw
- Most common design in trade and industry
- The saw blade cuts horizontally from above through the clamped workpiece
- Manual, semi-automatic or fully automatic blade lowering – depending on the model
- Ideal for cutting to length bar stock, tubes, square tubes and sections
- Mitre cuts up to -45° / +60° possible on many models
- The preferred choice in metalworking and metal fabrication
Vertical metal band saw
- The band runs vertically; the workpiece is fed by hand or mechanically
- Greater cutting height than with horizontal models
- Enables free-form cuts and complex contours
- The first choice for mould making and the machining of flat material
- Suitable wherever more than just straight cuts are required
Combination and swivel-frame band saws
- Can be used in either horizontal or vertical operation
- Maximum flexibility in confined spaces
- Ideal for smaller workshops with varying sawing requirements
What should you look out for when buying a metal band saw?
Band saws often differ much more significantly than they appear at first glance: a machine used daily in a metalworking shop to cut pipes to length has different requirements to a mitre band saw in metal fabrication or a high-performance machine for batch cutting in production. The following criteria will help you make a purchase decision that suits your needs in the long term:
- Cutting capacity (mm) The maximum cutting capacity – specified as the diameter of round material and the square dimension at 90° – determines which workpiece dimensions can be processed. For typical metalworking and installation tasks, machines with a round cutting capacity of 130–180 mm are sufficient. For heavy solid material or large sections, capacities of 250 mm and above are required.
- Cutting speed and control The optimum cutting speed depends directly on the material. Infinitely variable drives allow precise adjustment from low speeds for hard steels and stainless steel up to higher speeds for aluminium and non-ferrous metals. The following are guide values: structural steel approx. 40–80 m/min, stainless steel approx. 20–40 m/min, aluminium approx. 60–100 m/min.
- Mitre function A swivelling saw arm is required for angle cuts up to -45° / +60°. Double mitre machines allow mitre cuts in both directions and are indispensable in metalworking and wherever precise joints are required.
- Manual, semi-automatic or fully automatic Manual machines are suitable for occasional single cuts. Semi-automatic models with hydraulic arm lowering and automatic end stop reduce the operator’s workload and improve repeatability. Fully automatic systems with motorised feed are the right choice for series production and continuous industrial operation.
- Voltage: 230 V or 400 V Smaller workshop models operate on 230 V. Larger stationary machines with a motor power of 1.5 kW or more require a 400 V three-phase connection. Before purchasing, check which connection is available at your workplace.
- Coolant system When cutting stainless steel, titanium or high-alloy steels, a coolant system significantly extends the service life of the saw blade and improves the cut quality. Many professional models are equipped with this as standard or offer it as an option.
Still unsure which machine is right for your business? Our team of experts will be happy to help you choose the right metal band saw – contact us today.
Choosing the right saw blade
The saw blade is the key wear part in band saws – and the most common cause of poor cutting results if chosen incorrectly. The standard recommendation for commercial use is the bi-metal saw blade (M42): It combines a tough, springy back with high-alloy HSS tooth tips and reliably cuts many steels up to approx. 800 N/mm² tensile strength – depending on the material, even without coolant.
The rule of thumb for tooth pitch is: the thinner the wall thickness of the workpiece, the finer the tooth pitch. Thin-walled tubes require finer teeth, while solid material can tolerate coarser ones. A pitch that is too coarse for thin-walled material leads to the teeth breaking off. This is a particularly common mistake for beginners.
About metal saw bands
Metal band saw or circular saw – which is better?
Band saw or circular saw – this question arises sooner or later in every metal workshop. There is no one-size-fits-all answer: both machines have their strengths, and which is more suitable depends on the material and daily use:
- The metal band saw excels with solid material, thick-walled pipes and large cross-sections: precise cut, low noise, affordable saw blade (approx. €6–15), no sparks. The automatic lowering mechanism also allows for a largely autonomous cutting process.
- The metal circular sawis the right choice for thin-walled profiles and pipes when cutting speed is key: it cuts faster and produces particularly burr-free cut edges. The downside: higher noise levels, more expensive saw blades and limited capacity when cutting thick solid material.
If you have any questions about choosing the right machine, or if both options are suitable for your business: our team will be happy to advise you personally.
Special highlights of ELMAG’s metal band saws
Our range of metal band saw machines extends from compact workshop models to high-performance mitre band saws for industrial use. What all machines have in common: robust construction, precise cutting results and a comprehensive range of accessories.
- Precision thanks to ball-bearing-guided saw blade: Stable, clean blade guidance is essential for consistently accurate cuts – even during long runs and under load.
- Mitre cuts up to -45° / +60°: Selected models with a swivelling saw frame enable precise angle and double mitre cuts for professional joints in metalworking.
- Hydraulic frame lowering for comfortable operation: Semi-automatic models with hydraulically controlled feed reduce operator strain and ensure consistent cut quality without manual effort.
- Coolant system for the toughest applications: For stainless steel, high-alloy steels and continuous cutting, the coolant supply significantly extends the service life of the saw blade.
- 15-year spare parts supply guarantee: ELMAG guarantees a 15-year spare parts supply for all band saws in its range – a clear service advantage for commercial businesses and companies that rely on long-term investment security.
Locksmiths, metalworkers, plumbers and agricultural businesses rely on ELMAG machines because they deliver on their promises – in daily use, year after year. Our team of expertsis happy to assist with any questions regarding the right model selection or accessories .
Frequently asked questions
What is the difference between a horizontal and a vertical metal band saw?
A horizontal band saw cuts with a horizontal saw blade – the workpiece is clamped in place and the cross-slide is lowered. This design is ideal for cutting bars, tubes and profiles to length. With a vertical band saw, the band runs vertically and the workpiece is guided. This allows for free-form cuts and more complex contours, but does not usually offer a mitre function. Some stationary workshop models are designed as combination machines for both operating modes.
What are the advantages of a band saw?
Metal band saws impress in everyday workshop practice with a combination of precision, cost-effectiveness and versatility. The key advantages at a glance: The continuously running saw blade produces clean, burr-free cut edges with minimal material removal. Even solid material and large cross-sections, which push other saw types to their limits, can be machined with precision. Operation is comparatively quiet and produces few sparks, which improves working comfort and safety in the workshop. Bi-metal saw bands are inexpensive to purchase and can be changed quickly. Semi-automatic models with hydraulic arm lowering allow for hands-free operation – the machine saws independently whilst the operator carries out other tasks. With the correct cutting speed, almost all metallic materials can be processed: from structural steel and stainless steel to non-ferrous metals such as aluminium and copper.
What speed should a metal band saw have?
The correct cutting speed depends on the material and has a direct influence on the saw blade’s service life and cut quality. The following guidelines serve as a reference: structural steel and iron approx. 40–80 m/min, stainless steel approx. 20–40 m/min, aluminium and light metals approx. 60–100 m/min, brass approx. 40–80 m/min, copper approx. 20–40 m/min. Basic rule: the harder and tougher the material, the lower the cutting speed – excessively high speeds drastically reduce the service life of the saw blade and can damage the tooth tips. Machines with stepless speed control allow for precise adjustment and therefore offer a clear advantage when working with different materials.
What should you bear in mind when sawing metal?
For clean cuts and a long machine service life, a few basic rules are important: The workpiece must always be securely clamped in the vice – loose parts can damage the saw blade and pose a safety risk. Furthermore, it should never be pressed into the material with too much force; the feed rate should be even and adapted to the material. When switching between different types of metal – particularly between rusting steel and stainless steel – the band, workbench and vice mustbe cleaned to prevent contamination. Accessories such as safety goggles and, where necessary, ear protection are mandatory when using a power saw to cut metal. Dull or damaged saw bands should be replaced immediately – continuing to work with a defective band not only compromises the quality of the cut but also puts a strain on the motor.
How can I tell when the saw blade needs replacing?
Typical signs of a dull or damaged blade include a significantly increased effort required for cutting, a poor cut finish with burrs or tear-outs, excessive heating of the workpiece and a change in the sound of the saw. With regular use, a visual inspection of the tooth tips is recommended after each working day. Damaged or broken teeth are an immediate reason for replacement – a defective saw blade impairs the quality of the cut and can damage the machine. You can find suitable replacement saw bands in our range of metal saw bands.
SKU: 78007 Mitre bandsawing machine CY 260x200 G 36 / 72 m/min227 mm 150 mm 90 mm 260x200 mm 150x125 mm 85x85 mm 260x200 mm 2450 mm Show more€ 2.508,00€ 2.508,00 Incl. Tax€ 2.090,00 Excl. TaxIn stock, immediately available
SKU: 78940 BOMAR metal band saw model BasiCut 275.230 GANC - including automatic feed275x230 mm 2720 mm 27 mm 0.9 mm 0 - 60 ° 2 40/80 m/min 1100 W Show more€ 23.118,00€ 23.118,00 Incl. Tax€ 19.265,00 Excl. TaxResidual amounts available
SKU: 78991 BOMAR ALU underfloor circular saw model AL 400 S semi-automatic120 mm 120 mm 96 mm 110 mm 100 mm 85 mm 285 x 70 mm 150 x 40 mm Show more€ 12.564,00€ 12.564,00 Incl. Tax€ 10.470,00 Excl. TaxNormal-Price
SKU: 78900 BOMAR metal band saw EasyCut 275.230 DG275x230 mm 2720 mm 27 mm 0.9 mm 45-0-60 ° 2 40/80 m/min 700/1100 W Show more€ 5.880,00€ 5.880,00 Incl. Tax€ 4.900,00 Excl. TaxNormal-Price
SKU: 78904 BOMAR metal band saw Ergonomic 320.258 DGH320x250 mm 2910 mm 27 mm 0.9 mm 45-0-60 ° continuously variable 20 - 120 m/min 1500 W Show more€ 11.184,00€ 11.184,00 Incl. Tax€ 9.320,00 Excl. TaxNormal-Price
SKU: 78918 BOMAR metal band saw Workline 610.450 DGH610x450 mm 5200 mm 34 mm 1.1 mm 60-0-60 ° continuously variable 20 - 120 m/min 3000 W Show more€ 28.194,00€ 28.194,00 Incl. Tax€ 23.495,00 Excl. TaxIn stock, immediately available
SKU: 78532 MACC metal band saw SPECIAL 420 DIMax. 400 mm Max. 400 mm Max. 260 mm Max. 400 mm Max. 280 mm Max. 400 mm Max. 380 mm Max. 260 mm Show more€ 20.430,00€ 20.430,00 Incl. Tax€ 17.025,00 Excl. TaxResidual amounts available
SKU: 78911 BOMAR metal band saw Workline 410.280 DGH -Semi-automatic bandsaw
SKU: 78916 BOMAR metal band saw Workline 510.350 DGH510x350 mm 4780 mm 34 mm 1,1 mm 60-0-60 ° continuously variable 20 - 120 m/min 3000 W Show more€ 22.992,00€ 22.992,00 Incl. Tax€ 19.160,00 Excl. TaxResidual amounts available
SKU: 78515 MACC metal band saw SPECIAL 411 M/SMax. 300 mm Max. 240 mm Max. 140 mm Max. 180 mm Max. 280 mm Max. 220 mm Max. 140 mm Max. 160 mm Show more€ 12.696,00€ 12.696,00 Incl. Tax€ 10.580,00 Excl. TaxResidual amounts available
SKU: 78906 BOMAR metal band saw Ergonomic 340.278 DGH340x275 mm 3125 mm 27 mm 0.9 mm 45-0-60 ° continuously variable 20 - 120 m/min 1500 W Show more€ 12.828,00€ 12.828,00 Incl. Tax€ 10.690,00 Excl. TaxNormal-Price
SKU: 78905 BOMAR metal band saw Ergonomic 340.278 DG340x275 mm 3125 mm 27 mm 0.9 mm 45-0-60 ° continuously variable 20 - 120 m/min 1500 W Show more€ 8.388,00€ 8.388,00 Incl. Tax€ 6.990,00 Excl. TaxNormal-Price
