Band Saw Blade Sizes: Dimensions, Uses, and Selection Rules

You are new to band saws and you need to order blades. You look online and see blades listed as 59-1/2, 80, 93-1/2, 105, 44-7/8, and many other lengths. Some are 1/8 inch wide and some are 3/4 inch. Some are 3 TPI and some are 24 TPI. You need to understand what all these numbers mean and how to choose the right blade for your saw.

Band saw blade sizes are defined by four dimensions: length, width, thickness, and TPI (teeth per inch). Each dimension affects how the blade performs. Understanding these dimensions is the key to choosing the right blade for your saw and your work.

Blade Length

The length is the circumference of the blade loop. It is determined by the saw’s wheel diameter and the distance between the wheels. Each saw model requires a specific blade length. You cannot use a blade of the wrong length.

How to find your blade length: Check your saw’s manual. If you do not have the manual, measure the old blade. Lay it flat, mark a point, and measure around the loop back to the mark. Or look up the saw model online.

Common blade lengths:

• 30-9/16 inches: Milwaukee M12 compact
• 32-7/8 inches: DEWALT 20V compact
• 35-3/8 inches: Milwaukee M18 compact, DEWALT mid-size
• 44-7/8 inches: Milwaukee M18 deep cut, DEWALT deep cut, Makita 18V
• 56-7/8 inches: Some 10-inch metal saws
• 59-1/2 inches: 9-inch benchtop wood saws (Ryobi, Central Machinery, Skil)
• 62 inches: Some 10-inch wood saws (Craftsman)
• 64-1/2 inches: 4x6 horizontal metal saws (Central Machinery, others)
• 72-1/2 inches: Some 12-inch wood saws
• 80 inches: 12-inch wood saws (Craftsman 113, Delta 28-160, Jet JWBS-12)
• 93-1/2 inches: 14-inch wood saws (Delta, Jet, Grizzly, Powermatic)
• 105 inches: 14-inch wood saws with riser block
• 124 inches: Large industrial saws

Blade Width

The width is the distance from the back of the blade to the tip of the teeth. Width determines the minimum cutting radius and how well the blade tracks on straight cuts.

1/8 inch: Tight curves, minimum radius about 2 inches. Not for straight cuts. The narrow blade wanders on straight lines.

1/4 inch: General curves, minimum radius about 4 inches. Handles straight cuts in stock up to 2 inches. A good second blade for curve work.

3/8 inch: The best all-around width for most woodworking saws. Tracks straight for ripping and crosscutting. Still handles curves with a 5 inch radius or larger. If you only own one blade, make it 3/8 inch.

1/2 inch: Straight ripping and resawing. Handles the full resaw capacity of most 14-inch saws (6 inches, 12 inches with riser). Will not cut curves tighter than about 12 inch radius.

3/4 inch: Maximum width for most 14-inch saws. Resawing only. Some saws cannot accommodate 3/4 inch blades without modifying the guide post.

For portable metal saws: All portable band saws use 1/2 inch wide blades. The width is fixed by the saw design and cannot be changed.

Blade Thickness

The thickness is the gauge of the blade material. Thickness affects blade life and whether the blade will tension properly on your saw.

0.020 inches: Standard for portable band saws (Milwaukee, DEWALT, Makita). All portable saw blades are this thickness.

0.025 inches: Standard for 9-inch and 12-inch benchtop wood saws. Most consumer blades are this thickness.

0.035 inches: Standard for 14-inch and larger wood saws, and for horizontal metal saws. Thicker for more beam strength and longer life.

Important: Check your saw’s manual for the recommended blade thickness. Some 12-inch saws cannot tension 0.035 inch blades properly. Using a blade that is too thick for your saw’s tensioning system will cause tracking problems and premature blade breakage.

TPI (Teeth Per Inch)

TPI is the number of teeth per inch of blade length. It is the most important specification after length for determining cut quality and speed.

For Woodworking

3 TPI (hook tooth): Resawing thick stock (3+ inches). Large gullets clear chips fast. Aggressive hook angle pulls the blade through the wood. Fast but rough cut.

4 TPI (skip tooth): General woodworking. The default for most 1/4 and 3/8 inch blades. Handles 3/4 to 2 inch stock. Good balance of speed and finish.

6 TPI: Smoother cuts on 1/2 to 1 inch stock. Slower than 4 TPI but better surface finish. Good for furniture parts.

10 TPI: Thin stock (1/4 inch and under) and fine curves. Clean cut but will burn in thick material.

14 TPI: Very thin stock and scroll work. Smoothest edge but slow and prone to burning in anything over 1/4 inch.

For Metal Cutting

6 to 8 TPI: Thick bar stock (1-1/2 inches and up). Coarse teeth produce large chips that clear the gullets.

10 to 14 TPI: Medium thickness (1/4 to 1-1/2 inches). The most common range for general metal cutting.

14 to 18 TPI: Thin material (under 1/4 inch). Fine teeth prevent grabbing.

18 to 24 TPI: Very thin sheet metal and small rod. Fine teeth produce a clean edge.

Variable Pitch

Variable pitch alternates between two tooth spacings (like 10/14). This breaks up harmonic vibration, reduces noise, and produces smoother cuts. It also lets one blade handle a range of material thicknesses. Variable pitch is recommended for mixed work.

Tooth Profile

Hook tooth (positive rake): The tooth leans forward. Cuts aggressively. Best for thick stock and resawing. Can grab in soft woods if feed is too fast.

Skip tooth (0 degree rake): The tooth is straight up. Large gullet for chip clearance. The most common profile for general woodworking. Good in soft or gummy woods.

Regular tooth (slight negative rake): Cuts slower, produces the smoothest finish. Best for thin stock and fine work where surface quality matters more than speed.

Blade Material

Carbon steel: The cheapest option. Holds an edge for 2 to 4 hours in softwoods, 1 to 2 hours in hardwoods. Good for occasional use. Cost: 8 to 15 dollars.

Bi-metal M42: M42 high-speed steel edge on flexible backing. Lasts 3 to 5 times longer than carbon steel. Handles hardwood resawing. Can cut metal on saws with speed reduction. The best choice for most users. Cost: 15 to 35 dollars.

Carbide-tipped: Longest-lasting but expensive. 5 to 10 times longer life than bi-metal. Overkill for most hobby saws. Cost: 60 to 150 dollars.

How to Choose the Right Blade

Step 1: Determine the blade length. Check your saw’s manual or measure the old blade.

Step 2: Choose the width. For curves, use the narrowest blade that can handle the tightest radius you need. For straight cuts and resawing, use the widest blade your saw can accommodate.

Step 3: Choose the TPI. Match the tooth count to the stock thickness. Coarse teeth for thick stock, fine teeth for thin stock. A good rule: at least 3 teeth should be in the material at all times.

Step 4: Choose the material. Carbon steel for occasional woodworking. Bi-metal for regular use or hardwood resawing. Carbide for production work.

Step 5: Consider variable pitch. If you cut mixed thicknesses, choose a variable pitch blade. If you always cut the same thickness, constant pitch is fine.

FAQ

How do I know what size blade my band saw needs?

Check the saw’s manual. If you do not have it, measure the old blade by laying it flat and measuring around the loop. Or look up the saw model online.

What is the best all-purpose band saw blade?

For woodworking: 3/8 inch wide, 4 TPI skip tooth, bi-metal. For metal cutting: 10/14 TPI variable pitch bi-metal.

What TPI should I use?

Match the tooth count to the stock thickness. At least 3 teeth should be in the material at all times. Thick stock: 3 to 8 TPI. Medium stock: 10 to 14 TPI. Thin stock: 14 to 24 TPI.

What is variable pitch and should I use it?

Variable pitch alternates between two tooth spacings. It reduces vibration and handles mixed thicknesses. Use it when you cut both thick and thin material.

Can I use a thicker blade on my saw?

Check your saw’s manual. Some saws cannot tension thicker blades properly. Using a blade that is too thick causes tracking problems and premature breakage.

How wide of a blade can my saw use?

Check the saw’s manual for the maximum blade width. Most 14-inch saws can handle up to 3/4 inch. Most 9-inch saws max out at 3/8 inch. Portable metal saws use 1/2 inch blades only.

References

• Olson Saw. “Band Saw Blade Selection Guide.” Olson Saw Company.
• Timber Wolf Blades. “Blade Specifications and Sizing.” Suffolk Machinery Corporation.
• LENOX Tools. “Band Saw Blade Classifications.” LENOX Industrial Division.
• Starrett. “Bi-Metal Blade Specifications.” L.S. Starrett Company.
• Carter Products. “Blade Tension and Width Guide.” Carter Products.