If you have ever worked with a band saw — or even just looked at one in a workshop — you have probably noticed that the blade plays a huge role in how smooth, fast, and accurate your cuts are. Whether you’re cutting wood, metal, or plastic, choosing the right band saw blade size is the key to getting clean results and extending your blade’s life.
But here’s the problem — when you go to buy a new blade, there are so many numbers: length, width, thickness, teeth per inch (TPI) — it can get confusing quickly.
So, in this post, we will break everything down into simple language and include a Band Saw Blade Size Chart you can easily refer to anytime you need to pick the right blade.
Let’s get started.
What Is a Band Saw Blade?
A band saw blade is a long, continuous metal strip with teeth along one edge. It loops around two or more wheels in the saw, creating a constant cutting motion.
Because it cuts in a continuous loop, it’s perfect for smooth, consistent cuts — whether you’re cutting curves in wood, slicing metal pipes, or trimming plastic sheets.
Think of it like this:
- A circular saw cuts in quick spins,
- A jigsaw cuts back and forth,
- But a band saw blade moves continuously, giving smoother and more controlled cuts.
Understand Band Saw Blade Sizes
When someone says “band saw blade size,” they could be talking about a few different things. Each part of the blade’s size affects how it performs. Let’s break them down.
1. Blade Length
The blade length is the total distance around the blade loop — basically how long the blade is when you lay it flat.
Every band saw has a specific range of blade lengths it can handle, usually written on a plate near the machine or in its manual.
If your blade is too long, it won’t tighten properly. If it’s too short, it won’t fit at all.
💡 Tip: Always double-check your saw’s model before buying a new blade. A small difference in length (even ½ inch) can cause problems.
2. Blade Width
The blade width is the distance from the tooth tip to the back edge of the blade.
Wider blades (like ¾” or 1″) are great for straight cuts and resawing (cutting wood into thinner slabs).
Narrow blades (like ⅛” or ¼”) are better for cutting tight curves or intricate shapes.
Here’s a simple rule of thumb:
- Straight cuts → wider blade
- Curved cuts → narrow blade
3. Blade Thickness
The thickness of the blade affects how flexible it is. Thicker blades are stronger but less flexible, while thinner blades can bend around smaller wheels. If your saw has small-diameter wheels, you need a thinner blade — otherwise, it could crack over time from bending stress. For most 14″ band saws, a 0.025″ thick blade works perfectly. Larger saws (18″ and above) can handle thicker blades, like 0.032″ or 0.035″.
4. Teeth Per Inch (TPI)
The TPI (teeth per inch) controls how smooth or rough your cut will be.
Low TPI (2–6) = faster, rougher cuts
High TPI (10–24) = slower, smoother cuts
For example:
- 3 TPI → ripping wood or cutting thick materials fast
- 10 TPI → cutting thin metal or fine woodworking
- 14–24 TPI → cutting sheet metal or tubing
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Band Saw Blade Size Chart (Common Sizes)
Below is a quick reference chart for standard band saw blade sizes used in home workshops and small industrial machines.
| Band Saw Size | Blade Length (inches) | Common Blade Widths | Recommended Blade Thickness | Typical Uses |
|---|---|---|---|---|
| 9-inch band saw | 59 ½” | ⅛” to ⅜” | 0.014″–0.020″ | Small woodworking, hobby use |
| 10-inch band saw | 72″ | ¼” to ½” | 0.020″–0.025″ | Light wood cutting, DIY |
| 12-inch band saw | 80″ | ¼” to ¾” | 0.025″ | Medium-duty cutting |
| 14-inch band saw | 93 ½” | ⅛” to ¾” | 0.025″ | Most popular home shop size |
| 16-inch band saw | 105″ | ¼” to 1″ | 0.032″ | Resawing, furniture making |
| 18-inch band saw | 133″ | ½” to 1¼” | 0.032″–0.035″ | Heavy-duty wood or metal cutting |
| 20-inch band saw | 142″ | ½” to 1¼” | 0.035″–0.042″ | Industrial-grade cutting |
👉 Note: Always check your machine’s manual before ordering. Different brands (like Delta, Jet, or Grizzly) may use slightly different lengths.
Band Saw Blade Size PDF
This Band Saw Blade Size Chart PDF is a quick reference guide for choosing the right blade for your saw. It includes blade lengths, widths, thicknesses, and common uses for 9-inch to 20-inch band saws. Perfect for beginners, woodworkers, or metalworkers who want accurate, easy-to-read information in one handy printable chart.
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Choose the Right Band Saw Blade for Your Work
Let’s make this simple — here’s how to choose the right blade based on what you’re cutting.
1. For Woodworking
- Use low TPI blades (3–6) for fast, rough cuts or thick wood.
- Use medium TPI blades (6–10) for general woodworking.
- For curved cuts, choose a narrower blade (¼” or ⅜”).
- For resawing (cutting boards into thinner pieces), go with a wider blade (¾”–1″) and 3 TPI.
2. For Metal Cutting
Metal cutting requires stronger blades with more teeth.
- Thin sheet metal → 18–24 TPI
- Thick bar stock or pipes → 10–14 TPI
- Stainless steel → Bi-metal blades for durability
Also, keep your feed speed slower and use cutting lubricant to prevent overheating.
3. For Plastic and PVC
Plastic can melt if the blade gets too hot.
- Use medium TPI (6–10)
- Keep the feed speed steady
- If you notice melting, reduce the blade speed
How to Measure a Band Saw Blade
If your saw doesn’t have the length printed on it, don’t worry — you can measure it yourself.
Here’s a quick way:
Mark the blade: Use a piece of tape to mark the starting point.
Roll the blade flat: Use a tape measure to measure the full length around.
Check twice: Make sure you’re accurate to at least ¼ inch.
You can also use this formula if you know your saw’s wheel diameter and distance between wheels:
Blade Length = (2 × Center Distance) + (3.1416 × Wheel Diameter)
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Tips to Make Your Band Saw Blades Last Longer
A good blade can last months or break in days — depending on how you treat it.
Here are a few tips to make your blades last longer:
Break in new blades slowly: Run at half speed for a few minutes before cutting hard materials.
Keep it clean: Resin and pitch buildup can cause heat and wear. Clean your blade regularly with a blade brush or cleaner.
Use the right tension. Too tight = stress cracks. Too loose = wobbly cuts. Follow the manufacturer’s tension guide.
Choose the right tooth pitch: Wrong TPI can cause blade chatter or clogging.
Don’t force the material: Let the blade do the cutting. Pushing too hard can bend or dull the teeth quickly.
Common Problems with Band Saw Blades
Even the best blades have issues sometimes. Here’s what they mean and how to fix them.
| Problem | Possible Cause | Solution |
|---|---|---|
| Blade breaks quickly | Too much tension or small wheel diameter | Use proper tension and thinner blade |
| Cuts are wavy or uneven | Dull blade or wrong TPI | Sharpen or replace the blade |
| Blade slips off wheels | Improper tracking | Adjust wheel alignment |
| Material burns while cutting | Blade too fine or speed too high | Lower speed, use coarser blade |
| Blade jams in cut | Chips not clearing | Use fewer TPI or reduce feed pressure |
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Example: Choose a Blade for a 14-Inch Band Saw
Let’s say you have a 14-inch band saw in your garage and you want to cut both wood planks and metal rods.
You’d probably want two separate blades:
For wood: 93½” × ¾” × 3 TPI (wide blade for resawing lumber)
For metal: 93½” × ½” × 14 TPI bi-metal (fine teeth for smooth metal cutting)
Switching between them takes just a few minutes — and your results will be night and day.
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Why Blade Size and Type Matter
Think of your band saw like a guitar — if the strings (or in this case, the blade) are wrong or poorly tuned, the performance suffers.
Using the wrong blade size or type can cause:
- Rough, jagged cuts
- Blade breakage
- Motor strain
- Wasted material
But once you get the right combination, the saw runs smoothly, cuts effortlessly, and lasts much longer.
Final Thoughts
A band saw is one of the most versatile tools in any workshop, but it’s only as good as the blade you put on it. Knowing the right blade length, width, thickness, and TPI helps you cut more accurately, safely, and efficiently.
Whenever you are unsure, refer back to the Band Saw Blade Size Chart in this post — it will save you time, money, and frustration.
Whether you are crafting furniture, slicing metal sheets, or building something creative in your garage, the right blade will make your job not only easier but also much more enjoyable.
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FAQs:
What size band saw blade?
The size of a band saw blade depends on your machine’s model. Each saw has a specific blade length, width, and thickness it supports. You can find the correct size in the owner’s manual or by measuring the distance around both wheels. Common lengths range from 56 to 142 inches depending on saw size.
How do you size a band saw?
To size a band saw, measure the distance between the blade’s upper and lower wheels, then double that number and add half the wheel’s circumference. This gives you the correct blade length. Always check your saw’s manual, as it lists the exact blade size suitable for your model.
What is a 140 tooth saw blade used for?
A 140-tooth saw blade is designed for fine, smooth cuts. It’s commonly used for cutting thin metals, plastics, or finishing wood surfaces without leaving rough edges. The higher tooth count means a slower cut but much cleaner results, making it ideal for precision or decorative work.
How long is a 12-inch bandsaw blade?
A 12-inch bandsaw usually uses a blade that’s around 80 to 90 inches long, depending on the model. The “12-inch” refers to the saw’s wheel diameter, not the blade length. Always check your bandsaw’s manual or measure the exact distance between the wheels for accuracy.
How to select bandsaw blades?
When selecting a bandsaw blade, consider three things — material type, blade width, and tooth count (TPI). Thicker materials need fewer teeth per inch, while thinner ones need more. Choose a wider blade for straight cuts and a narrow one for curves. Always match the blade to your project’s material.
What does 24 TPI mean?
24 TPI means “24 teeth per inch.” It tells you how many teeth the saw blade has along one inch of length. A higher TPI gives smoother cuts but works slower, ideal for thin metal or fine wood. Lower TPI blades cut faster and are better for thicker materials.
What are the three types of band saw blades?
The three main types of bandsaw blades are carbon steel, bimetal, and carbide-tipped. Carbon steel blades are great for wood, bimetal blades work well for metals and tough materials, and carbide-tipped blades are used for heavy-duty cutting with excellent durability and long life.