35 3/8 Band Saw Blade: Choosing the Right TPI and Tooth Profile
You own a Milwaukee M18 FUEL Compact Band Saw and you need to order replacement blades. The saw takes 35-3/8 inch blades. You see three TPI options and you are not sure which one to use for the kind of work you do. You cut a mix of conduit, thin-wall pipe, unistrut, and occasionally sheet metal. You need a guide that helps you choose the right blade for each task.
The 35-3/8 inch blade is used by several compact portable band saws. It is one of the most common portable band saw blade lengths because it fits popular models from Milwaukee and DEWALT. Blades are widely available from Milwaukee, DEWALT, LENOX, MK Morse, and Starrett.
Saws That Use 35-3/8 Inch Blades
Milwaukee M18 FUEL Compact (2829-20): The current generation M18 compact saw. Brushless motor, 3-1/4 inch cut capacity.
Milwaukee corded compact (6230-20): The corded version of the compact saw. Same blade length.
Milwaukee older M18 compact (2629-20): The previous generation M18 compact. Same blade length.
DEWALT 20V XR Mid-Size (DCS378B): The DEWALT mid-size portable saw. Uses the same 35-3/8 inch blade.
Blades are interchangeable between all these models. The blade length, width, and thickness are the same.
Blade Specifications
| Specification | Value |
|---|---|
| Length | 35-3/8 inches |
| Width | 1/2 inch |
| Thickness | 0.020 inches |
| Material | Bi-metal M42 |
Available TPI Options
14 TPI
Part numbers: Milwaukee 48-39-0518, DEWALT DW3986 Best for: Medium wall pipe, thin bar stock, aluminum, angle iron. Material thickness: 1/4 to 1 inch. Characteristics: The coarsest blade for this length. Bites deep and clears chips fast. Faster cutting but slightly rougher finish.
When to use 14 TPI:
- Cutting medium wall steel pipe (up to 2 inches)
- Cutting aluminum bar and angle
- Cutting thin solid bar stock (1/4 to 1 inch)
- When cutting speed matters more than surface finish
When not to use 14 TPI:
- Very thin material (under 1/4 inch) where the coarse teeth will grab and tear
- Sheet metal where a fine finish is needed
18 TPI
Part numbers: Milwaukee 48-39-0519, DEWALT DW3987 Best for: Conduit, thin-wall tubing, unistrut, general-purpose cutting. Material thickness: 1/8 to 1/2 inch. Characteristics: The general-purpose blade and the factory standard. Handles the widest range of materials. The best starting point for most users.
When to use 18 TPI:
- Cutting EMT and rigid conduit
- Cutting thin-wall steel tubing
- Cutting standard 1-5/8 inch unistrut
- General-purpose metal cutting where you do not want to change blades frequently
When not to use 18 TPI:
- Very thick solid bar (over 1 inch) where the fine teeth will burn
- Very thin sheet metal where 24 TPI gives a cleaner cut
24 TPI
Part numbers: Milwaukee 48-39-0520, DEWALT DW3988 Best for: Sheet metal, small round stock, very thin-wall tubing. Material thickness: Under 1/4 inch. Characteristics: The finest blade for this length. Fine teeth prevent grabbing and tearing in very thin material.
When to use 24 TPI:
- Cutting sheet metal (20 gauge and thinner)
- Cutting small diameter rod (under 1/4 inch)
- Cutting very thin-wall tubing
- When you need the cleanest possible cut on thin material
When not to use 24 TPI:
- Material over 1/4 inch thick where the fine teeth will burn and load up
- Production cutting where the fine teeth dull too quickly
Tooth Profile
All 35-3/8 inch blades use a standard tooth profile with a 0 degree rake angle. The teeth are straight up, which provides a good balance of cutting speed and surface finish.
The compact saws do not have the motor torque to take advantage of hook tooth (positive rake) profiles, which are used on the deep cut saws for aggressive cutting of thick material.
Blade Material: M42 Bi-Metal
All 35-3/8 inch blades from Milwaukee and DEWALT are bi-metal with an M42 high-speed steel edge.
M42 edge hardness: 67 to 69 HRC. Hard enough to cut mild steel, aluminum, copper, and cast iron.
Backing steel: Flexible alloy steel that withstands the flexing around the saw’s wheels.
Maximum material hardness: M42 can cut material up to about RC 38 to 40. For harder materials, you need a carbide-tipped blade, which is not available in this length from Milwaukee or DEWALT. For carbide options, look at MK Morse.
Alternative Blade Brands
LENOX Wolf-Band
LENOX makes 35-3/8 inch blades in 14/18 variable pitch. The variable pitch breaks up vibration and handles a range of material thicknesses. LENOX blades typically outlast Milwaukee blades by 20 to 30 percent.
MK Morse
MK Morse makes 35-3/8 inch blades in 14 and 18 TPI. The Master Cobalt blades have a more aggressive tooth geometry that cuts faster than standard bi-metal.
Starrett
Starrett makes 35-3/8 inch bi-metal blades in various TPI options. Good quality and widely available.
Blade Break-In
New blades need a break-in period. Run the first 10 to 20 cuts at half feed pressure. This lets the sharp tooth tips wear evenly and prevents micro-chipping. Skipping break-in can reduce blade life by 30 to 50 percent.
Blade Life Expectations
| Material | TPI | Expected Cuts per Blade |
|---|---|---|
| EMT conduit (3/4 inch) | 18 TPI | 80 to 150 |
| Thin-wall tubing (1 inch) | 18 TPI | 80 to 150 |
| Medium wall pipe (1-1/2 inch) | 14 TPI | 50 to 100 |
| Aluminum bar (1/2 inch) | 14 TPI | 80 to 150 |
| Sheet metal (20 gauge) | 24 TPI | 100 to 200 |
| Unistrut (1-5/8 inch) | 18 TPI | 60 to 120 |
Quick Selection Guide
| If You Are Cutting | Use This Blade |
|---|---|
| Conduit (EMT or rigid) | 18 TPI |
| Thin-wall tubing | 18 TPI |
| Medium wall pipe | 14 TPI |
| Unistrut | 18 TPI |
| Aluminum bar | 14 TPI |
| Sheet metal | 24 TPI |
| Small round stock (under 1/4 inch) | 24 TPI |
| Angle iron (under 1 inch) | 14 TPI |
| General purpose (mixed work) | 18 TPI |
FAQ
What blade does the Milwaukee M18 compact band saw use?
A 35-3/8 inch blade in 1/2 inch width and 0.020 inch thickness. Available in 14, 18, and 24 TPI.
What TPI should I use for cutting conduit?
18 TPI is the best choice for conduit. It is the general-purpose blade and handles EMT and rigid conduit cleanly.
Can I use a DEWALT 35-3/8 inch blade in my Milwaukee compact saw?
Yes. The blade length, width, and thickness are the same. DEWALT and Milwaukee 35-3/8 inch blades are interchangeable.
What is the difference between 14, 18, and 24 TPI?
14 TPI is for thicker material (1/4 to 1 inch). 18 TPI is the general-purpose choice for most work. 24 TPI is for very thin material (under 1/4 inch).
Are LENOX blades better than Milwaukee for the 35-3/8 inch length?
LENOX Wolf-Band blades typically outlast Milwaukee blades by 20 to 30 percent. The variable pitch (14/18) is a good choice for mixed work. Both are good quality.
How often should I replace my 35-3/8 inch blade?
When the cut slows down, the blade starts wandering, or the cut surface becomes rough. A sharp blade cuts smoothly with light pressure.
References
- Milwaukee Tool. “M18 FUEL Compact Band Saw Owner’s Manual.” Model 2829-20.
- Milwaukee Tool. “Portable Band Saw Blade Specifications.” Milwaukee Tool Product Catalog.
- DEWALT. “Portable Band Saw Blade Reference.” DEWALT Product Catalog.
- LENOX Tools. “Wolf-Band 35-3/8 Inch Blade Guide.” LENOX Industrial Division.
- MK Morse. “Portable Band Saw Blade Comparison.” MK Morse Company.
