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What Can a Hole Saw Do?
A clean, perfect circle is the starting point for many projects. Whether you’re installing sleek downlights, running plumbing for a new sink, or fitting a lockset to a custom door, getting the right-sized hole is not just a detail — it’s the foundation of a professional finish. When a standard drill bit just won’t suffice, the hole saw becomes the hero of your toolkit.
However, staring at a wall of different hole saws can be confusing. Bi-metal, TCT, diamond-tipped… What’s the real difference between them, and which one will give you that perfect cut without burning out, cracking your material, or wasting your time?
This guide is here to clear things up. We’ll explain what hole saws are and how to choose the perfect one for your material, whether it’s wood, stainless steel, or tile. We’ll also answer some of the most common questions that arise on the job. Think of this as your definitive roadmap to drilling the perfect hole every time.
What Are Hole Saws?
Before we delve into the specifics, let’s start with the basics. A hole saw, also known as a hole cutter, is a specialised drill attachment designed to cut large, clean, circular holes in various materials. Imagine a cup-shaped blade with a serrated or abrasive edge — that’s your hole saw. Unlike a twist drill bit, which grinds away all the material inside the hole, a hole saw only cuts a circular outline, leaving a solid ‘plug’ of core material that can be easily removed.
This makes hole saws incredibly efficient for any task that requires a wider hole than a standard drill bit can make. Think about it:
- Cutting openings for recessed lighting in ceilings.
- Drilling perfectly-sized holes for pipes and plumbing fixtures.
- Creating clean entry points for cables and wiring.
- Installing new locksets and handles on doors.
- Making pathways for ventilation ducts through walls.
The true beauty of hole saws is their versatility. With the right tips, you can cut through most common building materials, including wood, metal, plastic, plasterboard, brick, glass, and ceramics.
How Do Hole Saws Work?
The genius of the hole saw lies in its efficiency. In contrast, a traditional drill bit has to pulverise all the material to create a hole, turning it into dust and shavings. This process is time-consuming and generates a lot of heat.
A hole saw, however, works smarter, not harder. By cutting only a thin circular path — the ‘kerf’ — it uses far less energy and completes the job much faster. Once the cut is complete, a neat disc of material (the plug) is left inside the saw. This plug can then be removed, leaving your hole ready to use. This is a good design when you need to make a hole that’s too big for a regular drill bit.
To keep the cut straight and prevent ‘walking’ or drifting across the surface, most hole saws use a pilot drill bit (or arbor). This is a standard twist drill bit that sits in the centre of the saw and protrudes slightly beyond the cutting teeth. You start by drilling the pilot hole, which anchors the hole saw in the exact centre of your circle. As you continue drilling, the pilot bit keeps the entire assembly perfectly aligned, ensuring your hole is straight and perfectly round.
How to Choose the Right Hole Saw？
Choosing the right hole saw for your project requires careful consideration of a few key factors. Making the right choice will save you time, money and frustration.
First, think about the size and depth of the hole.
- Diameter: This is the most obvious one. The diameter of the hole saw determines the width of the final hole. Always measure twice and choose a saw that matches the requirements of your fixture, pipe or hardware.
- Depth: The depth of the hole saw cup determines the thickness of material that can be cut through in a single pass. If the material you are cutting is thicker than the depth of the hole saw, you will have to stop partway through, remove the material plug and then continue the cut. To make a clean, one-action cut, always choose a hole saw with a depth greater than the thickness of your material.
Although removing the material plug can sometimes be difficult, many modern hole saws are designed to make this easier. Look for saws with large slots or ‘gullets’ in the side of the cup. These allow you to use a screwdriver to prise out the plug. Some premium models even feature ejector springs that automatically push the plug out once the cut is finished.
Another major consideration is the material you plan to cut. This is where choosing the right type of blade is crucial. Here’s a quick cheat sheet:
- For softer materials such as wood, plastic and drywall, a basic carbon steel hole saw will suffice.
- For general use across a variety of materials, including wood, plastic, aluminium and mild steel, a bi-metal hole saw is the most versatile and reliable option.
- For harder metals, especially stainless steel, you need a Tungsten Carbide Tipped (TCT) hole saw.
- For tough materials such as ceramic tile, stone, and glass, a diamond-tipped hole saw is essential.
When to Use a Metal Hole Saw？
The bi-metal hole saw is the go-to, all-round champion for most jobs. These are the workhorses of any toolkit. They typically have cutting teeth made from cobalt alloy high-speed steel (HSS), which is welded to a tough alloy steel body.
This bi-metal construction provides the ideal balance of strength and durability. They are tough enough to handle resistant metals such as mild steel and stainless steel, yet still effective for cutting softer materials such as wood, plaster, and plastic. If you’re a professional who needs a reliable tool that can handle whatever the job throws at you, investing in a quality set of bi-metal hole saws is a wise choice.
When to Use a Tungsten Carbide Hole Saw？
Although a standard bi-metal hole saw can cut through metal, it will quickly wear down if you regularly tackle thick or hardened steel. This is where the Tungsten Carbide Tipped (TCT) hole saw comes in.
Tungsten carbide is an extremely hard and heat-resistant material. TCT hole saws have their cutting teeth tipped with tungsten carbide, enabling them to power through tough metals with far less wear and much better heat dissipation. This means they cut faster and last significantly longer when used on metal.
For anyone who frequently works with steel, especially stainless steel, a TCT hole saw is the superior choice. Although they may be more expensive initially, their extended lifespan and cutting efficiency make them a more cost-effective tool for metal fabrication in the long run.
Which Hole Saw Should Be Used When Cutting Thin Stainless Steel Sheets?
As discussed, a bi-metal hole saw can be used for stainless steel, but a TCT hole saw is undoubtedly the better option for the best results. The carbide teeth are specially designed to handle the tough, abrasive nature of stainless steel due to their hardness. For example, our TCT hole saws feature a unique three-blade tooth design that enables them to cut through stainless steel smoothly and rapidly with less heat buildup and a cleaner finish.
Is Cutting Fluid Necessary When Cutting Stainless Steel Parts?
Many professionals use cutting fluid or another lubricant when drilling through metal. The fluid reduces the immense heat generated by friction, keeping the cutting teeth sharp for longer and preventing the metal from warping or discolouring. While not strictly necessary for every cut, using cutting fluid is good practice and will definitely extend the life of your hole saw, particularly when working with stainless steel.
How to Enlarge a Hole in Existing Drywall?
It’s a common scenario: you need to replace a 4-inch downlight with a 6-inch model, but how can you enlarge the existing hole if there is no centre point for your pilot drill? Don’t worry — there are a few clever tricks to help you.
- Use a plywood template: Take a piece of scrap plywood measuring around 8×8 inches and use your new 6-inch hole saw to drill a hole in the centre of it. Now you have a perfect 6-inch guide. Place the template over the existing 4-inch hole in the drywall and secure it with a couple of screws. Then use the template to guide your 6-inch hole saw for a perfect cut.
- The ‘plug’ method: A variation of the above. Use a 4-inch hole saw to cut a hole in a piece of scrap wood. The ‘wood plug’ left inside the saw will be a perfect 4-inch circle. Fit this plug into the existing 4-inch hole in your drywall. This plug will now give you a solid centre point from which to drill your new 6-inch hole.
- Some hole saws come with multiple blade sizes, so use an adjustable hole saw. You can often use the smaller inner blade as a guide to centre the larger outer blade for the new cut.
Can the Hole Saw Be Used Without a Center Positioning Drill Bit?
Yes, it’s possible, but you’ll need a guide. As mentioned in the drywall example above, you need either a clamping fixture or a template to hold the hole saw in place and stop it moving around your material. Without a pilot bit or guide, it’s hard to cut a clean, accurate hole.
Can Acrylic Holes Be Drilled Using Bi-Metal or Tct Hole Cutters?
Although it is possible to use a hole saw on acrylic, it can be difficult. Acrylic is brittle and prone to cracking, particularly when thin. To achieve the best results, leave the protective film on the acrylic and add a layer of tape over the area where you will be drilling. This will support the material and prevent chipping. Drill slowly and apply light pressure. However, many fabricators find that a step drill bit is easier to provide a cleaner and safer result on acrylic.
When to Use a Diamond Holesaw？
Even TCT won’t cut it when you’re faced with cutting through extremely hard, brittle materials. This is where diamond hole saws excel. Rather than having teeth, these saws have a continuous cutting edge that is coated in fine diamond grit — the hardest natural material on Earth.
The incredible hardness and heat resistance of diamonds make these saws the perfect tool for cutting clean, precise holes in materials such as:
- Ceramic and porcelain tiles
- Glass and marble
- Stone and granite
Choosing the Right Holesaw
Hopefully, this guide has made choosing the right hole saw less confusing. The next time you’re faced with that wall of options, just bear in mind these key points:
- For general-purpose cutting in wood, plastic, and some metals, a bi-metal hole saw is ideal.
- If you frequently cut metal, especially stainless steel, upgrade to a TCT hole saw for better performance and a longer lifespan.
- For tiles, glass, stone, and other hard ceramics, a diamond hole saw is essential.
- Always match the diameter and depth of the saw to the requirements of your project. The goal is to make the cut in a single, clean action.
Why Choose Galiptools
Galiptools is a leading manufacturer and exporter of precision cutting and drilling tools based in China. The company focuses on creating durable, high-performance solutions for professional users worldwide, including hole saws. With a strong foundation in engineering and manufacturing, Galiptools works closely with partner factories to ensure every product meets the demands of modern workshops and construction environments.
To learn more about their full range of hole saws and drilling solutions, visit galiptools.com
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