How To Cut Metal With A Dremel? Guide by an Expert’s

The Dremel multitool is arguably the most popular tool in the arsenal of any DIY enthusiast or woodworker.

How To Cut Metal With A Dremel

It is an extremely versatile handheld rotary tool that can use a host of attachments for different purposes.

And cutting metal is just one of many tasks that you can do with this tool.

However, when trying to cut metal with a Dremel, many users face a fair bit of trouble.

Cutting metal is not as easy as cutting wood and takes a certain level of preparation and precision. And if you do not know what you are doing, you can easily damage your material.

Well, that is where we come in. In this article, we will give you a quick and thorough rundown of how to cut metal with a Dremel so that you do not have to worry about going through this solely on your own.

Let’s Start……

What Is A Dremel Tool And What Is It Used For?

What Is A Dremel Tool?

Dremel is a multinational brand operating out of Illinois, USA, that is popular for its production of a unique type of rotary tool.

The most notable of their products is the Dremel 3000 and 4000 both of which have gathered a cult following over the years among hobbyists and DIY enthusiasts.

The rotary tool by Dremel is extremely versatile and can use a wide variety of attachments for accomplishing different tasks. Its primary functions include carving, routing, engraving, sharpening, cleaning, grinding, polishing, sanding, and cutting.

However, hobbyists over the years, have found many other uses for this versatile little machine. Here are a couple of innovative uses for the Dremel rotary tools.

• As A Screwdriver

You can use the Dremel rotary tool with a screwdriver bit to get a fully functioning automatic screwdriver.

Just make sure you always stick with the low-speed option on your tool. Otherwise, there is a chance of threading the screws and damaging them.

• For Calligraphy

Another fun little use that you can get out of a Dremel tool is in the field of calligraphy. You can pick up the Stylo Craft tool attachment for your Dremel and make detailed calligraphy quite easily.

And since the tool itself is so light and easy to use, you will have little trouble handling it and keeping it stable.

• To Groom Pets

This might be the most innovative use that you can get out of your Dremel rotary tool. If you have a dog or a cat in your house, you can use the Pet Nail Grooming Rotary attachment to give your pets thorough grooming.

Can a Dremel Cut Metal? A Very Exciting Question For The Reader

Can a Dremel Cut Metal? A Very Exciting Question For The Reader

Yes, a Dremel rotary tool can capably cut almost any type of metal as long as you are using the right cutting attachment.

It is an extremely versatile tool that can cut anything from sheet metal to aluminum if you know which bit is right for the task.

However, if you are planning to cut something made of hardened steel, this tool might not be the best choice for the task. This type of project requires a bit more power than what a Dremel rotary tool offers.

Okay, now we see how it works.

How To Cut Metal With A Dremel: Step-by-Step Guide

How To Cut Metal With A Dremel: Step-by-Step Guide Line

Before you start cutting metal with your Dremel tool, there is a fair bit of preparation involved.

  • Make sure you have your Dremel tool.
  • A cutting wheel attachment.
  • A pencil.
  • Adhesive tapes.

And your Dremel grinding attachment ready before you get started. If you have everything ready, here are the steps you need to follow.

Step 1: Preparing Your Workspace And Tool

Since you are planning to cut metal, there are a lot of preparations involved.

Cutting metals is not an easy task, and you will have to deal with all the sparks that will fly around when the Dremel tool connects to the metal.

So, you should only work in an area with good access to fresh air.

In addition, make sure you have a workbench and a clamp to hold the metal down in place while you cut through it.

You want to minimize the wobbling and ensure that the sheet metal is as stable as possible before you start cutting through it.

You also need to prepare the tool and use a cutoff wheel instead of the drill head that comes with your Dremel tool.

To do this first, you need to remove the drill head using a wrench. Then choose the right cutoff wheel depending on how accurate you want the cut to be and the thickness of the material that you are cutting.

Step 2: Marking The Cutting Area

Take a pencil and mark out the area where you want to cut by drawing straight or curved lines.

Your goal would be to cut carefully over the lines to minimize material wastage and damage.

Remember, the smaller the cut or incisions on the material, the better the Dremel tool will work.

Alternatively, you can go with adhesive tape strips to mark out the area you want to cut. Regardless of your choice, make sure you are tracing the cutting area perfectly.

You want to keep the cuts as clean and simple as possible so draw your lines accordingly.

Step 3: Cutting The Metal

Once you have your work area and cutting material ready, you can get started with the cutting process.

The Dremel tool works best when you are positioning the cutting wheel perpendicular to the cutting material.

You also want to hold the tool steadily with both your hands so that there is no wobbling. Then you want to set the right speed on your Dremel tool to cut the metal.

If you are working with thin metal sheets, you do not need to set the speed higher than the medium settings.

However, thicker sheets might need a bit more power. That is when the high-speed setting in the Dremel tool will come in handy.

When you are touching the metal with the cutting head of the Dremel tool, make sure to not apply too much pressure.

The grit in the cutter should do all the actual cutting. In addition, do not cut through entirely on the first cut. For best results, you want to do a few passes along the marked lines.

If you require higher levels of precision, you can change to a smaller attachment or bit. You should also be extremely careful while cutting the metal as sparks will fly around everywhere.

So, wear all the proper safety equipment before you start cutting the metal.

Step 4: Grinding And Finishing

After getting your desired cut, you will notice that the edges of the metal sheet are rough and sharp.

Before handling it, you need to sand the edges and smoothen it out so that it is safe to handle. So, switch to a grinding bit and start sanding down the edges to your liking.

While grinding, make sure you apply as little force as possible. Take everything slow and steady and do a couple of passes until you like the finish.

You can also use a paper sander after grinding if you want the edges to be even smoother.

Note: Here are our two relative articles How To cut PEX tube? and What tool to use for cutting PEX tubes? Guide With Video

Safety Tips: While Using A Dremel Tool

Safety Tips

Now that you have a clear idea of how to use a Dremel to cut metal, you must be itching to get started. However, before you do so, you need to think about your safety.

Working with metal sheets and any power tool is dangerous and must always be treated with respect.

Here are a couple of essential safety tips for anyone who wants to cut metal with a Dremel.

1. Wear Safety Gloves

Wear Safety Gloves

You should never use a Dremel tool barehanded. Make sure you are wearing a pair of high-grip safety gloves that allows you to hold the tool securely without any chance of dropping it.

If you drop the Dremel tool while it is in use, the outcome will never be good for you.

By wearing a pair of safety gloves, you can reduce the risk of accidents in your workplace to a large extent.

2. Wear Safety Glasses

Wear Safety Glasses

Safety glasses are also a must-have accessory for people who are planning to cut metal with a Dremel tool.

When the cutter connects with the sheet metal, the high friction produces sparks that fly around everywhere. If any of those sparks get in your eyes, they can seriously hurt you.

To prevent any permanent damage or injury, make sure you always wear safety goggles when you are using a Dremel tool.

3. Read Through the Manual

Read Through the Manual

The one thing that we always recommend people do anytime they get a new power tool is to go through the owner’s manual.

It contains all the information and tricks that your new Dremel tool can do. So, make sure you read through the manual before you actually start using it.

In fact, even when you know a bit about your tool, going through the manual can give you some additional bits of information that might come in handy.

Just browse through the manual quickly and you should have a fair bit of knowledge about your tool.

4. Familiarize with the Speed Settings

If you have never used a Dremel rotary tool before, then you should start with the speed settings first.

Of course, this is assuming that you have already read the owner’s manual and know how to access the speed adjustment of your machine.

Typically, a Dremel tool features three different speed modes, high, low, and medium. When cutting sheet metals, we mostly stick to medium settings.

But you should also try out the low and high-speed settings to get an idea of how it feels without actually cutting any material with it.

5. Workspace Safety

Workspace Safety

The place where you are planning to cut the metal also needs some attention if you want to have a safe work experience.

Make sure there are no loose wires or cables lying around where your tool might get caught.

You also want to get rid of any trip-hazards on the floor before you start cutting the metal sheets with your tool.

In addition, make sure there is enough lighting in the room so that you can see everything clearly.

Since you are making small cuts, if you want your cuts to be accurate, you need a well-lit environment.

Frequently Asked Questions

1. Can I polish metal with a Dremel tool?

Yes, you can. In fact, it is one of the primary purposes of a Dremel rotary tool. After grinding the metal sheet that you cut, you can switch to a polishing bit and start polishing it to perfection.

3. Should I go with a corded or a cordless Dremel rotary tool?

It depends on your preference. Dremel has a couple of excellent cordless units that work on rechargeable batteries.

The battery life is pretty decent, and the power is also quite good. If you want a truly cordless experience, going with a cordless Dremel tool is not a bad idea at all.

However, with corded units, you do not have to worry about charging the batteries or the power running out in the middle of a project.

4. What other tools does Dremel make?

In addition to their rotary tools, Dremel also makes hot glue guns, butane tools, scroll saws, and a couple of other unique tools, accessories, and attachments.

You can categorize their entire catalog into two primary segments, Compact Tool Systems, and Benchtop Tool Systems.

Final Words

Cutting metal with a Dremel can feel a bit troublesome at first, but after a couple of tries, you will easily get the hang of it.

This versatile tool is extremely handy at cutting through a wide variety of materials. So, cutting through thin metal sheets or aluminum is not all that difficult.

We hope our complete guide on how to cut metal with a Dremel was easy for you to follow and replicate.

Stay with us for more valuable articles. Good luck!

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