Stainless steel sheets are widely used in many industries due to their durability, corrosion resistance and smooth surface finish. However, due to their different thicknesses, stainless steel sheets need to go through multiple processes in construction, and these processes may vary from project to project.

Cutting stainless steel sheets requires choosing the right cutting method based on the sheet thickness, accuracy requirements and available tools. Here is a structured guide:

1. Factors to consider when cutting stainless steel

Stainless steel is challenging to cut due to its characteristics, which affects cutting efficiency. Issues such as the reduced hardness of the material, its heat resistance and the tools used for cutting come to the fore:

Material properties

Stainless steel is hard and chemically resistant, making it suitable for many applications, but it is difficult to shape. Excessive heat during cutting can cause it to deform, while its hardness causes rapid wear of the tool.

Sheet thickness

The nature of the work depends on the thickness of the material, thin sheets can be cut by hand or with small machines, while thick sheets require large machines such as plasma cutting or water jet cutting. Thermal management is essential.

Cutting tool durability

Due to the characteristics of stainless steel, special tools such as carbide or industrial laser tools are needed for cutting. It is essential that these special tools can cut freely without causing any damage to the stainless steel during the cutting process.

Thermal management

Since this is difficult, suitable tools such as carbide tools and industrial lasers are needed. They use special cutting equipment to achieve better results while avoiding damage to the equipment during the cutting process.

Accuracy requirements

Depending on the project needs, the highest accuracy defines the cutting tools and techniques. Laser or water jet cutters can make fine cuts, while for simpler cuts, simple tools such as shears or scissors are used to cut thin sheets.

2. Tool selection and applicable thickness

Thin sheets (≤1.2mm, such as below 18 gauge)

Hand tools

Aviation shears (tin shears): suitable for straight or curved cutting, flexible but laborious operation, need to cut in small sections to reduce deformation; suitable for small projects.

Electric shears (Nibbler): cut by punching small sections of material, suitable for complex shapes, reduce sheet warping and deformation.

Laser cutting: high precision, burr-free, suitable for industrial needs, but requires professional equipment support.

Best practices

››Reduce heat
In general, thin stainless steel is susceptible to heat, causing warping or discoloration. If you use the right tool speed and, if necessary, coolants such as cutting fluid and water jets, you may be able to effectively avoid this.

››Stabilize the paper
Make sure it is firmly fixed to the surface to be cut and ensure that it does not move while working. This will avoid going through inappropriate areas and causing more scratches on the sheet; resulting in better, cleaner, and more accurate cuts.

››Deburr the edge
Sharpness refers to the possibility of sharp edges or roughness on the grain and bottom of the area after cutting. It is recommended to use a deburring tool or sandpaper so that you can trim safely and achieve the desired appearance.

Medium and thick plates (1.2-3mm, such as less than 1/8 inch)

Power tools

Jig saw (with bimetallic saw blade): Use 18-24 TPI fine-toothed saw blade, cut at low speed and use coolant to cool down to avoid overheating and hardening.

Circular saw (carbide blade): Need to use a guide ruler to ensure straight cutting, spray cutting oil to reduce friction.

Plasma cutting: Suitable for fast cutting of thick plates, but requires an air compressor and protective equipment, and the cut may need to be polished.

Cooling technology: Heat is never a problem for stainless steel, but the cooling process during cutting may cause deformation or fatigue. Tools such as water, air and cutting fluid can minimize wear on the material, thereby improving the durability of the blade.

Thick plates (≥3mm, such as 1/4 inch and above)

Angle grinder (special grinding wheel for stainless steel): medium speed cutting, avoid high temperature causing hardening of the material, and wear protective equipment.

Plasma cutter: suitable for industrial environment, requires air compressor and protective equipment, efficient cutting of thick plates.

Laser/water jet cutting: no heat affected zone, extremely high accuracy, suitable for high-precision processing of complex shapes, but the cost is higher.

Cutting fluid and lubrication: Hydraulic shears are very suitable for straight-line cutting of thin-gauge stainless steel, especially for thick plates. Hydraulic shears are able to apply huge pressure to achieve clean and thin cuts in the shortest time, so they are ideal for applications that require a lot of work.

Tips: To cut thick stainless steel plates, plasma cutters, water jet systems, and industrial lasers must be used to maintain the quality of the material. It is well known that air conditioning and regular maintenance can improve performance and durability.

3. Key operating skills

Temperature control

Stainless steel has poor thermal conductivity and is easily hardened or deformed due to high temperature. Use coolant (such as cutting oil) or incremental feed method to reduce cutting temperature and extend tool life.

Avoid continuous high-speed cutting and pause heat dissipation at appropriate times to prevent local overheating.

Tool and parameter optimization

Tool material: Carbide or cobalt-containing high-speed steel tools are preferred for better wear resistance.

Cutting parameters: Low speed and high torque (such as when drilling), with lubricants to improve surface finish.

Feed mode: Incremental feed (non-continuous cutting) can reduce heat accumulation and reduce temperature by more than 30% compared to radial feed.

Subsequent treatment

Deburring: Polish the cut with a file, sandpaper or angle grinder to ensure safety and beauty.

Pickling cleaning: If you need to remove the oxide scale, use mixed acid (such as HNO₃+HF) for pickling, but the time must be controlled to avoid excessive corrosion.

4. Material characteristics and adaptation methods

Austenitic stainless steel (such as 304/316): strong ductility, easy to stick to the knife, requires high hardness tool and sufficient cooling.

Molybdenum-containing stainless steel (such as 316): high corrosion resistance, but high cutting resistance, it is recommended to use low speed with high lubricity coolant.

Easy-to-cut type (such as 303): contains sulfur or selenium elements, which can increase cutting speed, reduce tool wear, and is suitable for high-speed processing.

5. Safety and maintenance

Personal protection: goggles, cut-resistant gloves, dust masks (to avoid inhalation of metal dust).

Equipment inspection: regularly replace worn blades/grinding wheels to ensure cutting efficiency and safety.

Environmental management: maintain ventilation, stay away from flammable materials, and clean up metal debris in time.

Summary: Cutting stainless steel plates requires comprehensive consideration of thickness, material and tool conditions, with priority given to controlling temperature and tool wear. For high-precision requirements, it is recommended to outsource laser/water jet cutting; in daily operations, carbide tools + coolant + incremental feed are the most practical solutions. Be sure to be familiar with thin, medium and thick cutting techniques, and pay attention to clean, safe and precise cutting dimensions to ensure that every cut is flawless.