A guide to panel cutting

Panel cutting can be a daunting task. There are a lot of health and safety precautions to follow to reduce the risk of injury to yourself and damage to your tools and materials. So we have written our top tips to cutting panels including the recommended tools to use.

The best tool to cut metal sheets is a circular saw because they are non-abrasive and produce minimal heat. This means they won’t melt plastic or painted coatings, but they will make a lot of noise and vibration, so be aware. 

Steel sheet nibblers create a long punch cut and allow you to make consecutive punches in a straight line. They’re great for trimming sheets down and for corners, flashings and details. If you’re looking for a rounded edge, we recommend a metal sheet nibbler. 

Cutting Mulitple Sheets of Metal

If you’re cutting multiple metal sheets, use a circular saw. Ensure the saw has a metal cutting blade attached, we recommend carbide-tooth blades as they last longer. You may require a little more pressure when cutting multiple sheets. 

Cutting Wood

For cutting wood, we recommend a circular saw for easy and accurate cutting. But you can also consider using table saws, jigsaws, Sabre saws, and utility knives. The sharper the tool, the neater the cut which means splintering is less likely. 

Cutting Plastic PVC

Cutting plastic PVC panels is a little easier than cutting metal or wood panels as you don’t have the risk of splintering or sharp cut-offs. You also don’t need power tools to cut them and there are multiple ways to do it. 

Hand saws 

A hand saw is the most preferred tool to use. It requires a fairly low skill level but it does need a lot of concentration and effort. 

Score and Break Method 

If you’re looking to achieve clean cuts quickly, we recommend the score and break method. As long as your plastic sheets are under 5mm thickness, you can achieve a clean break every time. 

Jigsaw

A jigsaw can provide more efficiency in cutting plastic panels. It requires less concentration and can achieve cuts much quicker.

How To Cut Metal Roof Panels In 4 Steps

Lay The Panels On a Flat Surface 

Lay the sheet panel you plan to cut on a flat and stable surface to ensure the sheets don’t move when you start to cut. We recommend a workbench as it can hold the sheet in place with adjustable clamps. The ridges must be facing down to be easier to cut across. 

Mark The Lines Before You Cut 

Using a tape measure, mark where you want the cut to begin and end. Measure the sheet multiple times to make sure you’re accurate. 

How To Cut Wood Panels 

Cutting wood panels isn’t as easy as you might think. There are many things to consider, especially if you are trying t avoid splintering. Here are the top three tips we’ve found when cutting wood panels. 

Watch Your Cutting Techniques 

• Make sure the face of the panel is pointing downwards to ensure a clean cut. 

• Cut along the grain to avoid splintering. 

• Use masking tape along the length of the cut as a guide 

• Score your marked cutting line to reduce splintering 

PPE For Metal Cutting

• Ear defenders

• Full face welding masks and protective eyewear 

• Sturdy footwear 

• Protective gloves

• Full length trousers and long sleeves

For more information on panel cutting and to check out the tools available to help you, take a look at 4 Cladding Services.