Is Higher TPI Better for Metal?

When it comes to cutting metal with a reciprocating saw blade, one question that often comes up is whether higher TPI (teeth per inch) is better for the job. Metal cutting reciprocating saw blades are designed to tackle a variety of metals.

However, the choice of blade depends largely on the material's thickness and the type of cut you're aiming to make. In this blog, we’ll break down how TPI impacts metal cutting and guide you toward choosing the best Sawzall blades for metal.

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Understanding TPI and Its Role in Cutting Metal In Reciprocating Saw Blade(s)

The TPI (teeth per inch) of a rsbis one of the most important factors when deciding what blade to use for metal.

TPI affects how quickly and smoothly a saw blade cuts through material. Higher TPI means more teeth in contact with the material, which leads to smoother cuts, but it can also slow down the cutting process. Lower TPI, on the other hand, removes material faster but may leave a rougher edge.

Low TPI vs. High TPI for Metal Cutting

• Lower TPI (4–8 TPI): Best for thick or soft metals like steel pipes, rebar, or scrap metal. These metal Sawzall blades are ideal for rough cuts and demolition, where speed and cutting through tough materials are more important than the finish quality.
• Higher TPI (10–18 TPI): Ideal for cutting thinner metals like sheet metal, aluminum, or fine tubing. Metal cutting reciprocating saw blades with higher TPI deliver cleaner, smoother cuts but can take longer to make progress.

Generally, for general metal cutting, medium TPI (6–10) works well for a balanced combination of speed and smoothness, but you’ll want to choose a blade that fits the specific metal you're cutting.

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What Makes the Best Sawzall Blades for Metal?

Choosing the right Sawzall blade for metal isn’t just about the TPI. It’s also about the material and build of the blade itself. Bi-metal rsbs  and carbide-tipped blades offer superior durability when cutting through hard metals, reducing the likelihood of blade wear or breakage.

1. A Bi-Metal RSB Blade

Bi-metal rsb are a combination of high-speed steel (HSS) teeth and a spring steel body, making them durable yet flexible. These blades are great for cutting through a wide range of metals, including thin sheet metal, aluminum, and light to medium steel.

If you’re looking for metal cutting Sawzall blades, bi-metal blades are a versatile choice, offering excellent performance and longevity across a variety of metal materials.

2. Carbide-Tipped Sawzall Blades

For heavy-duty jobs like cutting through cast iron, steel rebar, or thick metal, carbide Sawzall blades are often the best choice. Carbide-tipped blades offer maximum wear resistance and are perfect for tackling abrasive metals or metal cutting reciprocating saw blades for tougher materials. For instance, EZARC’s 8 TPI carbide reciprocating saw blade is designed for thick metal, cast iron, and alloy steel, offering great performance in tough conditions.

Carbide blades may not be the fastest when it comes to cutting thin metals, but they’ll last significantly longer than standard bi-metal blades in heavy-duty scenarios.

3. Choosing the Right Length and Thickness

Apart from TPI and material, consider the length and thickness of the blade. If you're working in tight spaces, a shorter blade (6–9 inches) might give you more control, while longer blades (12 inches or more) allow for deeper cuts. Thicker blades tend to resist bending and provide greater stability when cutting tough metal, especially when cutting through thicker or denser materials.

For more on selecting the right Sawzall blade, check out our comprehensive guide on how to choose the right Sawzall blade here.

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Best Sawzall Blades for Metal

When selecting reciprocating saw blades for metal, it’s important to match the blade to the specific material and thickness you’re cutting. Below are some of the best Sawzall blades for metal from EZARC, which provide excellent performance and durability for various types of metal cutting.

• EZARC 8 TPI Carbide Reciprocating Saw Blade for Thick Metal & Cast Iron
  Perfect for tough demolition jobs, these blades can handle thick metal, cast iron, and even high-alloy steel. The carbide teeth ensure long-lasting durability, even in the harshest environments.
  Check it out here.
• EZARC 10 TPI Carbide Reciprocating Saw Blade for Medium Metal Cutting
  If you need a versatile metal cutting Sawzall blade for medium-duty cuts in steel or aluminum, this blade provides excellent balance, combining the ability to cut through various thicknesses while maintaining smoothness and speed.
  Get it here.
• EZARC Bi-Metal Reciprocating Saw Blades for Metal & Wood Demolition
  For those tackling mixed materials, these bi-metal blades handle both wood and metal demolition with ease. They feature strong HSS teeth and flexible spring steel bodies, offering great performance for light to medium metal cutting jobs.
  Explore the range.

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Key Takeaways: TPI and Metal Cutting

When it comes to cutting metal, choosing the right reciprocating saw blade depends on several factors, including TPI, blade material, and thickness.

• For rough cuts in thicker metals, lower TPI (6-8) will get the job done faster, but may leave a rougher edge.
• For cleaner cuts in thin metals or precise applications, opt for higher TPI (10-18).
• Consider bi-metal or carbide-tipped blades for enhanced durability, especially when dealing with tough metals like cast iron or steel.

If you’re still unsure, check out our full selection of reciprocating saw blades for metal here, where you’ll find the best options for every kind of metal cutting project.

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Conclusion

Ultimately, higher TPI is not always better for metal cutting—it depends on your project’s needs. By understanding the material you're working with and selecting the right rsb , you’ll get the best performance and results. Whether you're cutting thin sheet metal, heavy-duty steel, or tackling demolition projects, the right blade makes all the difference.