Best Hole Saw for Thick Metal (2026)

Compared on paper

Specifications are as published on each listing and collected 30 October 2026. Where a listing states no cutting depth or metal thickness, the table says so rather than filling the gap.

How the points were given

Each saw is scored on performance, build, value, safety where it applies, and warranty, with performance, build and value weighted heaviest. No listing here states a safety certification or a warranty term with a concrete length, so every saw scores zero for safety and warranty, and the ranking comes from stated metal cutting ability, cutting depth, range and contents.

Scores run from 9.2 to 9.8: each product’s point total is placed on that range, so more points always means a higher score. Safety counts only for powered gear or where the listing states safety features; where it does not apply, the score is taken over the remaining 90 points.

What the listings tell you

5 listings were compared. 4 are bi-metal sets or saws and 1 is a TCT carbide saw. Only 1 states a stainless steel thickness, at 3 mm, and only 1 states an iron plate thickness, at 15 mm. Cutting depth is stated for 2 of the 5, at 2-3/8 in and 40 mm, and 1 saw states thin metals only with stainless steel excluded. That spread is why the ranking leans on what each listing states for metal, not on blade counts alone.

Buying guide: best hole saw for thick metal

Tooth material: bi-metal or carbide

Bi-metal saws pair high-speed steel teeth with a flexible steel body, and 4 listings here use that build for general metal cutting. The TCT carbide saw is the exception: it states industrial grade TCT carbide steel for hard metal, alloy, aluminum, stainless steel, plastic and iron. For thick or hard stock, the stated material matters more than the piece count, since a bi-metal set that names soft metal or thin metals is not claiming the same job.

Cutting depth and metal thickness

Depth decides whether a hole goes through in a single pass. The Diablo set states a 2-3/8 in cutting depth, and the HYCHIKA kit states a maximum cutting depth of 40 mm. Thickness is stated only for the TCT saw: 3 mm stainless steel, 15 mm iron plate and 15 mm aluminum alloy. The other listings state no metal thickness, so judge them on depth and stated uses rather than on a thickness figure they never give.

Size range and arbors

Range decides how many hole sizes one purchase covers. The Diablo set holds 10 cups from 7/8 to 2-9/16 in with a Snap-Lock Plus mandrel that fits Diablo sizes from 5/8 to 6 in. The LifeIdeas set holds 12 blades from 3/4 to 2-1/2 in with 2 mandrels, and the HYCHIKA kit holds 11 blades from 3/4 to 2-1/2 in with 2 mandrels. The VIKITON saw is a single 6 in saw with an arbor included, while the TCT saw is a single 2 in saw with no arbor stated, so check the arbor line before ordering a single saw.

Cooling and chip removal

Heat dulls teeth fast in metal, and the listings give two kinds of help. The VIKITON tips say to apply water or coolant and reduce feed speed when drilling metals, and to let the saw cool before touching it. The TCT listing says to use a lubricant, water or oil, so the bit will not overheat, and describes double round circles that clear metal filings. The HYCHIKA kit adds a chip removal groove on the side of the saw, and the LifeIdeas set describes a spiral chip flute that clears chips in all directions.

Garage Fit Check

• Match the saw to the metal: the TCT saw states 3 mm stainless steel, while the VIKITON saw states thin metals only with stainless steel excluded.
• Check depth before ordering: the Diablo set states 2-3/8 in and the HYCHIKA kit states 40 mm maximum, while the other listings state no cutting depth.
• Check the arbor: the VIKITON saw includes an arbor, the Diablo mandrel fits Diablo sizes from 5/8 to 6 in, and the TCT saw states no arbor.
• Coolant on hand: water or coolant for the VIKITON saw, and water or oil as a lubricant for the TCT saw, so keep one ready before the first hole.
• Storage: the HYCHIKA kit comes in a storage box and the LifeIdeas set in a portable storage case, so the sets stay sorted between jobs.

FAQ: garage tools

What hole saw cuts thick metal?

A carbide saw with a stated thickness for the metal in question is the strongest match here: the TCT saw states 3 mm stainless steel, 15 mm iron plate and 15 mm aluminum alloy. Bi-metal sets cut metal generally, but only the Diablo set states a deep 2-3/8 in cutting depth, and none of the bi-metal listings states a metal thickness.

Bi-metal or carbide for thick metal?

Carbide, where the listing states it: the TCT saw is made of industrial grade TCT carbide steel for hard metal, while the bi-metal listings pair high-speed steel teeth with a flexible steel body for general metal work. The HYCHIKA kit names soft metal among its uses, and the VIKITON saw names thin metals only, so neither claims the hard-metal job the TCT saw states.

What cutting depth do I need?

Match depth to the stock: the Diablo set states a 2-3/8 in cutting depth for deep holes in a single pass, and the HYCHIKA kit states a maximum cutting depth of 40 mm. The TCT, LifeIdeas and VIKITON listings state no cutting depth, so check the stock thickness against the depth line of the listing before ordering.

Do I need coolant when cutting metal?

The listings say yes in plain terms. The VIKITON tips say to apply water or coolant and reduce feed speed when drilling metals, and to stop at once if abnormal vibration occurs. The TCT listing says to use a lubricant, water or oil, so the bit will not overheat, and to wear protective goggles and gloves during use.

Can a hole saw cut stainless steel?

Only one listing here states it: the TCT saw states cutting on 3 mm stainless steel. The VIKITON saw excludes stainless steel outright, and the other listings state metal generally without naming stainless. For stainless work, pick the listing that states stainless cutting rather than assuming a bi-metal set covers it.

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