How To Cut Metal With A Dremel (From Hobbyist to Pro)

If you have a Dremel, you must have used it for a variety of tasks. But have you tried it on any metal project?

Can Dremel really cut metals? If so, what’s the correct way to do so, or which Dremel tool is best for cutting metal? 

You may cut small metal components such as metal sheets, screws, pipes, and bars using the appropriate Dremel tool and method. EZ Lock Metal Cutting Wheel, Dremel Angle Grinders Cutting Wheel, and Dremel Cutting Wheels #420 and #409 can all cut metal up to an inch thick. The best disc for cutting tough metals is the 38mm Dremel Diamond Cutting Disc with EZ Lock Metal system.

I’ve included a concise overview and some useful advice in this article to assist you.

How To Cut Metal With Dremel

One of the best tools for all types of do-it-yourself projects is the Dremel. However, cutting heavy metal or hardened steel with this method is not recommended. For such task, a chop saw or a metal cutting saw is preferable.

However, Dremel excels at working with thin metal sheets, screws, bolts, rods, and similar materials.

Dremel metal cutting demands the right skills and knowledge:

Step 1: Implement Required Safety Measures

Taking the appropriate safety precautions is the first step.

There will be a lot of sparks and scrap metal when you start to cut it. Wear protective glasses and a mask to avoid breathing in the flying metal debris to avoid getting it in your eyes.

You’ve covered your face, but what about your bare hand and other exposed body parts? You do realize that the sparks won’t only hit your face? Therefore, you can wear full-sleeved clothing to protect your skin.

You see, the sparks produced when metal is sliced are short-lived and won’t even badly burn or injure you. It might only annoy you slightly.
However, if you’ve ever used a Dremel, you’re probably used to the unpleasant drill sound it makes when you turn it on.

Use your earbuds to listen to this. I believe listening to music is far preferable then listening to drilling noise.

Step 2: Get Your Metal Ready

Prepare the metal surface before moving on to the cutting phase. Thoroughly remove any rust or dirt from the metal.

This is crucial because rust will break off as soon as you begin cutting if there is any. Therefore, you won’t get the precise cut you want.

After that, you must measure and mark the area where you wish to make the cut. You can apply tape or a marker. This will ensure accurate cuts and help you stay on task while cutting.

Last but not least, fasten the metal piece so that it doesn’t sway during cutting.

Step 3: Learn Which Dremel Tools Are Used For Metal Cutting

Dremel has produced a broad variety of attachments taking into account various sectors and needs. For cutting metal, they have more than ten wheels made of abrasive material bonded with fiberglass.

I’ve covered the top 5 metal-cutting tools in this article:

Wheel 1: Dremel EZ Lock Metal Cutting Wheel #SC456

These wheels are perfect for cutting bolt heads, slotting damaged screws, cutting sheet metal, or trimming metal rods. You can make quick and precise cuts in metal with these. 


Easily Fits into tight spaces and produces less dust. You will get a thin and perfect line cut with these wheels. 


Doesn’t last long. If you press too hard, the fiber disc will separate from the central Dremel. 

Wheel 2: Dremel EZ406- Lock Starter Kit

These cut-off wheels are generally reinforced with fiberglass. So you can easily cut, trim, or grove metals, including Hardened steel.

It has 0.45” thick blades. These kits come with a storage case to keep all the accessories organized. 


Last 2X longer than other cut-off dices. Easy to use.


Weak for grinding. Needs to be careful while inserting the disc, or it can break initially. 

Wheel 3: Dremel Angle Grinder Metal Cutting Wheel

Dremel Angle Grinders are designed for high-performance metal cutting. With these wheels, you can cut carbon steel, stainless steel, mild steel, metal pipes, tubes, or flat sheets exceptionally fast.


Delivers fast and consistent cuts.


Produces highly annoying noise and vibration. 

Wheel 4: Dremel #409 Cut-Off Wheel

These wheels are best for tough applications such as hardened steel and wood. With its 0.6 mm thick blade, you can cut all kinds of metals smoothly.


Gives straight and precise cuts. These are cheaper and produce fewer sparks.


Doesn’t last long. If you give an extra sideway pressure, these will break.

Wheel 5: Dremel #420 Cutting Wheel

Dremel #420 Cutting Wheels are ideal for cutting, grooving, and trimming all kinds of metal. You can easily cut or slice any hard but not-so-thick steel with these wheels, such as bolts or screws. 


Cheaper and more durable than other Dremel cutting wheels.


Though these wheels last long if you are not careful, these discs will break, and pieces of shrapnel will fly.

Step 4: Select the ideal Dremel tool for cutting metal

Having knowledge of the most popular Dremel metal cutting tools, you must now select the ideal Dremel tool for your project.

Examine each of the tools I described above, then pick the one that best suits your requirements and your budget.

Step 5: Set Up the Cutting Wheel

Put the metal-cutting wheel you’ve selected into the Dremel. Now modify the Dremel’s speed in accordance with the metal’s thickness.

You must set the Dremel to 30000 to 35000 RPM (Revolutions per minute) when working with any thick metal.

On the other hand, thin metal can be worked at speeds between 25000 and 28000 RPM. A slower pace offers greater accuracy.
Sixth step: start the Dremel
Turn on the power while holding the Dremel correctly.

Step 7: Start Cutting

You are now prepared to begin cutting. Move it gently along the cutting line. Keep your hand stable and the tool level at all times.

Avoid using excessive pressure because doing so could cause the wheel to crack and detach from the main Dremel. Little pressure should be used during the cutting.

Step 8: Switch the Dremel off

Once the cut is complete, switch off the Dremel and unplug it from the outlet.

Step 9: Finishing and Polishing

After the cut, there may be burrs or jagged edges. To polish the edges, use sandpaper or a grinding stone.

Polish the metal’s surface after that. Your metalwork will have a professional finish as a result.

Step 10: Put the Dremel away

Sometimes we neglect to organize the equipment and its accessories once the cut is complete. Your favorite Dremel may become less durable as a result of this kind of carelessness.

Therefore, each time you use your Dremel, make sure to store it as directed.

Expert Tips for Better Results

Here are a few tips to make your metal-cutting experience smooth:

  • When we work with any rotary tools, the right speed is the most important factor. To get the desired cut, set the speed of the Dremel according to the instruction given above. 
  • For curved cuts or intricate designs use a diamond cutting wheel. 
  • Avoid overheating the metal by keeping the Dremel moving at a consistent speed around the metal. Instead, take a break. It will also prevent hand fatigue. 
  • At 25000-28000 RPM, it’s obvious that a lot of heat has been produced. So do not touch the cutting wheel or the metal immediately after cutting.

Using a Dremel to cut steel

Dremel is not the ideal option for cutting hardened steels, as I already stated. To work with hardened steels, certain instruments are available.

However, Dremel will complete the process when it involves little steel tasks. For cutting steel, there are particular Dremel cutting discs.

A 38mm cutting disc can cut through steel. But for cutting all kinds of steel, even hardened steel, the 38mm Diamond Cutting Disc will be your best bet.

With my 38mm diamond cutting disc, I have cut a padlock. It effortlessly cut through that tarnished shackle.

Because it reduces the longevity of the Dremel and the cutting disc, I don’t suggest using it on severely hardened steels.

However, if you have a 38mm Diamond Cutting Disc and the most powerful Dremel 4300, you can cut anything with ease, including tough steels.

Questions and Answers

Can I Use a Dremel to Cut Thick Steel?

With Dremel high-performance cutting wheels, thin steel may be sliced. For cutting steel, a speed of 35000 RPM is advised. Do not go over the allowed RPM.

A 38mm Diamond Cutting Disc is capable of cutting thick steel.

Avoid using a Dremel to cut steel if you have a standard disc. Use a tool made for the task, such as a chop saw or a metal cutting saw, instead.

Which Dremel Is Best for Metal Cutting?

The best tool for cutting metal is the Dremel 4300. Its powerful motor and 5000-35000 RPM allow you to easily cut various types of metal.


You see, metal cutting is not as difficult as it first appears. It’s an easy operation if you use the proper Dremel tool for cutting metal and technique.

Make sure you have taken all essential safety precautions, selected the appropriate Dremel tool, and prepped the metal surface before beginning to cut metal with a Dremel.

You will be able to use your Dremel to cut metal like a pro by paying attention to the procedure, advice, and techniques mentioned above. So, feel free to give it a go!

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