How thick of a material can a band saw cut?

The Key Factor: Throat Capacity vs. Cutting Capacity

First, it’s crucial to understand the two main measurements of a band saw:

1. Throat Capacity: The distance from the blade to the vertical frame of the saw. This determines the width of material you can cut.

2. Cutting Capacity (or Height under the Guide): The distance from the table to the upper blade guides when they are at their highest point. This is the measurement that determines the maximum thickness a band saw can cut.

1. By Saw Type and Size

The size and type of the band saw are the primary determinants.

• Small Benchtop Band Saws (9″ – 10″):

  • Typical Max Thickness: 4 to 6 inches (100 – 150 mm).

  • Use Case: Ideal for hobbyists, model makers, and small woodworking projects.

• 14-Inch Stationary Band Saws (The Workshop Standard):

  • Typical Max Thickness: 6 to 12 inches (150 – 300 mm). The classic 14-inch models like the Delta or Jet typically have a 6-inch capacity under the guides, but many can be fitted with a “riser block” kit to increase this to 12 inches.

  • Use Case: The workhorse for serious woodworkers and metalworkers (with the correct blade and speed).

• Large Industrial Vertical Band Saws (18″ – 36″ +):

  • Typical Max Thickness: 12 to 24+ inches (300 – 600+ mm).

  • Use Case: Used in lumber mills, shipbuilding, and large-scale metal fabrication for resawing thick lumber or cutting large metal stock.

• Horizontal Band Saws:

  • Typical Max Thickness: This is defined by the size of the material that can fit in the vise. Common sizes range from 4×6 inches up to 20×20 inches or more.

  • Use Case: Primarily for cutting metal bar stock, pipe, and tubing to length. The “thickness” here is the cross-sectional height of the material.

2. By Material Type

The hardness and density of the material play a huge role in practical cutting capacity.

• Wood: A band saw can handle its maximum rated capacity in most woods. However, cutting a 12-inch thick piece of hard maple is much more demanding on the motor and blade than cutting soft pine of the same thickness.

• Metal: The effective capacity for metal is significantly less. Cutting a 6-inch thick piece of aluminum is possible with a powerful saw and the right blade, but cutting a 6-inch solid steel bar is a job for a large industrial horizontal bandsaw or a very powerful vertical saw. Friction sawing with a special blade can be used for very thick, but not necessarily precise, metal cuts.

• Plastics & Composites: Generally similar to wood, but some abrasive composites (like G10) will quickly wear out standard blades.

3. Other Critical Factors That Affect Practical Cutting

Even if a saw is rated for a certain thickness, you need the right setup to achieve it.

• Blade Width and TPI (Teeth Per Inch):

  • Wider blades are stronger and better for resawing thick material as they resist twisting and track straighter.

  • Lower TPI blades (e.g., 2-3 TPI) have larger gullets (the space between teeth) which allow for better chip removal when cutting thick stock. A fine-tooth blade will clog and overheat.

• Motor Power: A underpowered motor will bog down and stall in thick, dense material. A 1 HP motor is a good minimum for serious resawing on a 14-inch saw.

• Blade Guides and Setup: Properly adjusted guides are essential for keeping the blade stable and preventing it from deflecting or twisting, which ruins the cut and can break the blade.

Summary Table

*Often requires a riser block for the higher end of this range.

Conclusion

To find out how thick a material your band saw can cut:

1. Check the manual for the “Cutting Capacity” or “Height under Guide.”

2. Ensure you have the correct blade: a wide, low-TPI blade for thick materials.

3. Respect the material: Don’t expect a small saw to cut thick steel effectively.

For most home workshops, a 14-inch band saw with a 6-inch to 12-inch capacity is more than adequate for the vast majority of tasks.