Cut Sheet Metal Without Curling

The method you choose to cut sheet metal depends on the thickness of the metal and the type of cut you plan to make.

Cut sheet metal without curling.

You can cut the sheet metal without too much distortion and noise when you use a nibbler. There are some cuts that you can do with decent tin snips. The illustrations are for a small bracket but i have cut 3 foot long pieces using this method. To cut straight lines use an electric saw.

The fastest way to cut sheet metal in complex shapes or straight lines without a shear is a plasma torch. These photo steps show that it can be done using a utility knife. If you want the speed of a power tool you can get an electric metal shear and get straight cuts without curling your metal. Such as straight cut snips left cut the right cut etc.

Start by taping both sides of the sheet metal directly over the line you want to cut and clamp the metal to a work station so it doesn t move. It works best only if there is a small project since it will require more effort on your end which is why it may not be the best for beginners. If you use metal shears to cut thin sheet metal such as duct metal it curls and can be difficult to flaten properly. Plus a plasma torch can be used for thick metal too so they are really handy.

When set to a low amperage a plasma torch won t warp the metal and can yield quick clean cuts that help you get the job done quickly. They look like scissors and work fine with sheet metals like brass aluminum tin steel etc.