Hole Saw for Cutting Thick Metal

Every now and then, there is a need to cut through a thick metal sheet at home or in factories and industries. A hole saw remains one of the best pieces of equipment that allows you to do this.

best hole saw for cutting thick metal
hole saw

One reason is the efficiency it affords, and another is the ease with which it allows you to cut through thick metal sheets. Knowing the importance of a hole saw, you may want to get one for immediate or future use. Thus, the question remains, ‘which hole saw is the best buy?’ and ‘what do you consider before getting one?’

This article seeks to answer these questions. In this article, you will get a detailed rundown of the best hole saws in the market. You will also get an explanation of the considerations you should make before getting a hole saw, either for personal or industrial use.

Quick Comparison of 6 Best Hole Saw for Metal

ProductKey SpecificationsMore Info
Top 6 Best Hole Saw For Cutting Thick Metal of 21st Century 1
Milwaukee 49-22-4185 Hole Saw
Bit : 28 piece
Compatible: metal/wood
Weight: 13.55 lbs.
Dimension: 9.5x16.5x4.75 in.
Rating: 508 ratings
Top 6 Best Hole Saw For Cutting Thick Metal of 21st Century 2
Klein Tools 31872 Hole Saw
Bit : 4 piece
Compatible: metal
Weight: 1.4 lbs.
Dimension: 6x4x4 in.
Rating: 449 ratings
Top 6 Best Hole Saw For Cutting Thick Metal of 21st Century 3
DEWALT D180002 Hole Saw Kit
Bit : 9 piece
Compatible: Wood/Metal
Weight: 3.25 lbs.
Dimension: ‎10.63x3.5x11.88 in.
Rating: 698 ratings
Top 6 Best Hole Saw For Cutting Thick Metal of 21st Century 4
Bosch Bi-Metal Hole Saw
Bit : 25 piece
Compatible: metal/wood
Weight: 6.71 lbs.
Dimension: 9.5x16.5x4.75 in.
Rating: 214 ratings
Top 6 Best Hole Saw For Cutting Thick Metal of 21st Century 5
SUNGATOR Bi-Metal Hole Saw
Bit : 18 piece
Compatible: metal/wood
Weight: 3.77 lbs.
Dimension: 10.59x8.58x3.11 in.
Rating: 937 ratings
Top 6 Best Hole Saw For Cutting Thick Metal of 21st Century 6
DEWALT D180005 Hole Saw
Bit : 14 piece
Compatible: metal/wood
Weight: 4.69 lbs.
Dimension: 3x9.8x7.3 in.
Rating: 578 ratings

Understanding a Hole Saw and Its Important Components

Another important aspect of getting a hole saw is understanding how its components work. This will not only help you make an informed buying decision, but you will also find the use of the hole saw easy and simplified.

Important Parts of a Hole Saw

The following are important components of a hole saw and its working principles.

Important Parts of a Hole SawArbors

This component is also known as a mandrel. It has two functions in a hole saw. The first one is to connect the drill chuck, and the hole saw. The second function is to hold the pilot bit. Both of these functions are important as they are integral to the operation of the hole saw.

The arbor is usually made out of strong steel and alloys. This is because they need to be durable as their operation lasts through numerous saws.

Choosing between an attached or detachable arbor

Both of these arbors have their inherent benefits. You have to decide which benefits appeal most to you. The detachable arbor means that you can use the arbor with any hole saw. You do not need to get a new arbor for every hole saw you get.

On the other hand, an attached arbor eliminates the stress of detaching and re-attaching arbors when using a new hole saw.

Pilot Bits

The primary function of pilot hole bits is drilling holes in metal and other materials. The drilling activity’s oscillating movement in most hole saws makes the pilot bits an important part of the hole saw.

Top-Rated 6 Best Hole Saw kit Reviews

Many hole saws out here get labeled the best hole saw. However, it is common knowledge that not all of these hole saws are that good. Some are better than each other.

The following is the review of the best hole saws for cutting thick metal:

1Milwaukee 49-22-4185 Ice Hardened Hole Saw Kit – 28 Piece

Milwaukee 49-22-4185 Ice Hardened Hole Saw Kit – 28 Piece

  • Saw Kit: 28 Piece
  • Compatible: Wood, Metal
  • Weight: 13.55 lbs.

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Highlight Features:

  • Possesses sharp tooth design for easy cutting.
  • Last for a long time.
  • Comes with a span that covers between 3/4 and 4-3/4 inches.
  • 22 hole saws and 3 drill bits included.
  • Durable and easy to use.

This hole saw is a whole new generation of metal cutting saw, possessing features that allow it to cut through metals and wood with little or no hassle. One of the saw’s impressive features is its cryogenic hardening process, which results in a stronger and lasting metal cutting saw.

The USA-made Milwaukee 49-22-4185 is an excellent tool that allows you to work with iron brass, copper sheet, stainless steel, wood, and metal drilling. The hardening process replaces the conventional heat treat process. Thus, the hole saw can overcome the problem of the surface metal wearing away.

Another important feature is the use of Matrix II bi-metal for its construction and is ideal for a wide range of applications. This feature allows for a durable, accurate, and rapid cutting process.

2Klein Tools 31872 Hole Cutter, 4-Piece Carbide Hole Saw Kit

Klein Tools 31872 Hole Cutter, 4-Piece Carbide Hole Saw Kit

Saw Kit: 4 Piece | Compatible: Iron | Weight: 1.4 lbs.

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Highlight Features:

  • Carbide-tipped edges allow for easy cutting and slicing.
  • Ejector springs built into the pilot bit.
  • Comes with 3 hole bits and one extra pilot bit.

The maker of this hole saw has a reputable name in the industry. Known for manufacturing tools and equipment that sees people’s demand, there is no doubt that this hole saw will remain one of the best in the market.

Without missing a beat the build-in ejector spring of the pilot bit allow you to drill straight from one hole to the next. It’s also has a built-in stopper, or flange to prevent accidental over drilling. The hole saw cuts easily into steel, iron brass, and copper sheet. It also allows you to work with steel in different forms, such as stainless steel and mild steel.

Features of the hole saw include an integrated flange system that prevents the over-drilling of metal sheets. There is also a split point pilot drill whose work is to prevent any form of bit walking. The carbide hole cutting range of the hole saw is between 7/8 and 1 3/8. The features of the hole saw make it useful for a long period.

3DEWALT D180002 Hole Saw Kit, Standard Electrician’s Set, Bi-Metal

DEWALT D180002 Hole Saw Kit, Standard Electrician’s Set, Bi-Metal

  • Saw Kit: 6 Piece
  • Compatible: Wood, Plastic, Metal
  • Weight: 3.25 lbs.

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Highlight Features:

  • Bi-metal construction hole saw.
  • Contains all you need with regards to metal cutting.
  • Comes in different sizes.
  • Quick plug ejection for easy plug removal.
  • Durable and long life.
  • Portable hand case.

This hole saw comes from another reputable brand, which has made a name for itself in the industry. The hole saw kit contains everything you may require for metal cutting activities. And as an upside to many of its counterparts, it comes in different sizes.

The use of quality material in manufacture the hole saw kit seems like the DEWALT Hole Saw kit’s best feature. Due to this quality material, the durability of the hole saw is vouchsafed.

Another upside is the presence of the case. The case allows for easy conveyance of the hole saw kit.

4Bi-Metal Hole Saw Kit From Bosch, 25-Piece

Bi-Metal Hole Saw Kit From Bosch, 25-Piece

  • Saw Kit: 25 Piece
  • Compatible: Wood, Metal, Stone
  • Weight: 6.49 lbs.

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Highlight Features:

  • Enough hole saws to cater to your needs.
  • 8% cobalt alloy construction.
  • Higher heat resistance.
  • Durable.
  • Possesses an impressive quick-change bit system.
  • Comes with 11 hole saws, pilot bit, and washers.

When it comes to quality hole saws for thick metals, you can never go wrong with the Bi-Metal Hole Saw Kit From Bosch.

The primary feature that you would enjoy with this hole saw kit is its quick-change bit system. This feature allows you to replace hole saws as quickly as possible. While this is an exciting feature, it also creates a problem.

The feature allows for a wobbly drilling process as the connection between the mandrel and the hole saw is not as strong as it ought to be. Thus, rather than get a clean hole after drilling metal sheets, what you get is a ragged hole. This, we believe, is the major downside to the hole saw.

5SUNGATOR’s Bi-Metal Hole saw Kit, 18-Piece

SUNGATOR’s Bi-Metal Hole saw Kit, 18-Piece

Saw Kit: 18 Piece | Compatible: Wood, Plastic, Metal | Weight: 3.77 lbs.

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Highlight Features:

  • Bi-metal construction for rustproof.
  • Greater heat resistance.
  • Durable and long life.
  • You get a carrying case and a spare pilot bit.
  • Ejection spring for easy plug removal.
  • Comes with 10 hole bits and one spare pilot bit.

With its bi-metal construction system, you know you have no business getting a new hole saw after you get the SUNGATOR’s 18-Piece Bi-Metal Saw Kit. The hole saw kit is strong and durable which a life expectancy estimated at 1.5X that of most hole saws.

When you get this saw kit, you get a pilot hole bit, a mandrel adapter, and a hard case.

All of these accessories ensure that you enjoy the use of the hole saw kit. The kit also features numerous hole saws of varying sizes to cater to your metal-cutting needs.

Comes with 10 hole saws (3/4″, 7/8″, 1-1/8″, 1-3/8″, 1-1/2″, 1-3/4″, 2″, 2-1/8″, 2-1/4″, 2-1/2”), one spare pilot drill, one large mandrel, one small mandrel, and a plastic case for easy storage.

6DEWALT D180005 Hole Saw kit, 14-piece

DEWALT D180005 Hole Saw kit, 14-piece

Saw Kit: 14 Piece | Compatible: Metal | Weight: 4.69 lbs.

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Highlight Features:

  • Bi-metal construction.
  • Versatile.
  • Ejection spring allows easy plug ejection.
  • Up to 50% longer life
  • Strong and efficient.

Another impressive product from DEWALT, the 14-piece hole saw kit is designed mainly for lighter metal sheets, plastic, and wood. The hole saw kit comes with an impressive number of hole saws, mandrels, and other accessories necessary for cutting or drilling holes into metal, wood, and other variety of materials.

The kit also possesses injector prongs which allow for the better usage of the quick-change bit system.

Comes with 11 hole bits (3/4, 7/8, 1, 1-1/8, 1-3/8, 1-1/2, 1-3/4, 2, 2-1/8, 2-1/4, 2-1/2), one spare pilot bit, and a storage case.

Best Hole Saw Kit Buyer’s Guide

Knowing the best products on offer in a market is not enough to make a buying decision. You need to buy products that work perfectly for you. As a result, you need to consider some factors while making this decision. Some of the factors are as follows:

Manufacturer’s Reputation

In the business world today, brands mean a lot. One of the major indicators of a quality product is the reputation of the manufacturer. Brands that are popular or reputable, in most cases, are usually safe as their popularity stems from past quality products.

Thus, when you go for reputable brands, you are sure to get excellent customer service, quality product servicing (when needed), and many other benefits. Knowing a reputable brand is easy. You can go through customer reviews or do some research as to their past offerings. These steps will help you identify manufacturers with solid reputations.

Cutting Ability/Effectiveness

This factor is a no-brainer. The purpose of having a hole saw in the first place is to cut and drill holes into metal sheets and other materials. Thus, you should be sure that the hole saw you are getting is capable of cutting or drilling the type of material you handle.

Also, the cutting efficiency of the hole saw matters. Some hole saws get dull or inefficient with time. It would help if you avoided these types of hole saw. Ensure that the hole saw you possess strong teeth for cutting your preferred materials without damage to the saw itself.


One thing is sure; you don’t want to go back searching for a new hole saw days or weeks after getting one. This is why you need to go for durable hole saws that will last you for a long period. You can check for the durability of a hole saw in two ways.

The first one is to check the product’s warranty period. As a rule of thumb, most durable products made from quality materials usually have a longer warranty period. The second method is to read up on past customers’ reviews. This review will give you an insight into the durability of the product in recent times. However, you should not rely entirely on customers’ reviews as some manufacturers pay for fake reviews.

These are some of the important considerations you need to make when purchasing a hole saw. Using these factors as a guideline will help you select the best and ideal hole saw for your personal or industrial use.

Additional Information/FAQs

What is the best hole saw for metal?

It isn’t easy to single out a certain hole saw as the best. The decision will depend on numerous factors, including its cutting efficiency, durability, and many other factors.

However, the Milwaukee 49-22-4185 All Purpose Professional Ice Hardened Hole Saw Kit 28 Piece offers excellent drilling and cutting operations on metals.

How thick of steel can a hole saw cut?

Hole saws can cut steel that is as thick as 25mm. This thickness is the highest we have seen, and only hole saws with a carbide tip can effectively carry out the cutting.

Who makes the best hole saw?

The answer to this question is debatable as there are numerous makers of quality and excellent hole saws.

However, the manufacturers of hole saws reviewed in this article rank top among the best hole makers. These manufacturers are DEWALT, Milwaukee, The Klein Family, and many others.

What Is a Hole Saw?

Hole saws are tools that allow you to drill holes and cut materials into different sizes. The hole can work on these types of materials; metal, stainless steel, wood, and plastic sometimes.

Can Hole Saws Cut Through Metal?

A good hole saw should cut through metal easily. While most hole saws cut through softer materials such as plastic and wood easily, the good ones also cut through-hardened steel, mild steel, and other metal types.

How Is a Hole Saw Measured?

Two major measurements matter when it comes to hole saws; bit diameter and cutting speed. The bit diameter is the size of the hole saw, while its cutting speed refers to the speed at which the saw cuts through certain materials.

You can measure the bit diameter in millimeters (mm), and the unit for cutting speed is meter per minute (m/mins). The cutting speed of a hole saw depends on the material to be cut and differs from one material to another.

What are the Factors to Choose a Perfect hole saw for cutting thick metal?

The factors to consider while choosing a perfect hole saw are numerous. However, the following are the most important considerations:

  • Cutting efficiency
  • Warranty
  • Manufacturer’s reputation and
  • Durability.

If you can ensure that the hole saw you are to buy passes the aforementioned considerations, you can be certain that the hole saw you would be ideal for the use intended.

Does It Matter What Material the Hole Saw Is Made of?

The material used to manufacture the hole saw does matter. The material affects the cutting ability of the saw and its durability, in most cases.

What are the Uses of Hole Saw Kits?

Hole Saw kits contain hole saws of different sizes for cutting and drilling metals and other materials.

Final Words

When it comes to cutting metals or drilling holes in metals, half of doing the job right is getting the right tools. Having the right tools make your work easier, faster, and even neater. However, getting the right hole saw is not as easy as it sounds, given the number of hole saws out there in the market.

To help you select the best hole saw, we highlighted some of the important considerations you should make when purchasing your hole saw. These considerations include the ability of the hole saw to cut, its durability, and the reputation of its maker.

We also examined some of the frequently asked questions about hole saws. These questions will give you insight into the basics of a hole saw and things you need to know before getting a new one. Lastly, we reviewed six of the best hole saws in the market.

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