How to Cut Expanded Metal: 2 Easy Beginner-Friendly Methods

Table of Contents#

1. Pre-Cut Prep: Safety & Essential Checks
2. Method 1: Angle Grinder Cut (Best for Thick, Large Sheets)
3. Method 2: Tin Snips Cut (Best for Thin, Small Projects)
4. Pro Tips for Perfect, Clean Cuts Every Time
5. Troubleshooting Common Cutting Issues
6. Final Thoughts
7. References

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Pre-Cut Prep: Safety & Essential Checks#

Before you start cutting, take 10 minutes to complete these prep steps to avoid injury and ensure a clean cut:

Required PPE (Personal Protective Equipment)#

• ANSI Z87.1 certified safety glasses with side shields to protect against metal shavings and sparks
• Cut-resistant work gloves (avoid loose cotton gloves, which can catch on metal strands)
• Ear protection (foam plugs or earmuffs) if using power tools
• Steel-toe boots if cutting full 4x8 foot expanded metal sheets to protect against falling offcuts

Pre-Cut Steps#

1. Measure twice, mark once: Use a permanent marker and straight edge to draw your cut line, making small hash marks across every raised metal strand so you don’t lose the line while cutting.
2. Secure the sheet: Clamp the expanded metal to a sturdy workbench on both sides of the cut line to eliminate vibration and shifting.
3. Pick the right method:

• Use the angle grinder method for sheets 18 gauge or thicker, or long straight cuts across full sheets
• Use the tin snips method for sheets 20 gauge or thinner, small cuts, or curved/irregular shapes

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Method 1: Angle Grinder Cut (Best for Thick, Large Sheets)#

A standard 4.5-inch angle grinder is the fastest, most efficient tool for cutting thick expanded metal, and it delivers clean, straight cuts with minimal fraying.

Tools Needed#

• 4.5-inch angle grinder
• 1mm thin metal cut-off wheel (thinner wheels produce less heat and fewer burrs)
• Clamps
• Straight edge (optional, for guided cuts)
• Metal file or 80-grit sanding pad
• PPE as listed above

Step-by-Step Instructions#

1. Prep your work area: Clear all flammable materials (paper, wood, fabric) from at least 10 feet of your work space, as angle grinders produce hot sparks that can ignite fires.
2. Inspect your cut-off wheel: Check for cracks or chips before installing it on your grinder, and tighten the wheel nut securely per the manufacturer’s instructions.
3. Align and start cutting: Hold the grinder at a 15–20 degree angle to the metal surface, and align the edge of the cut-off wheel with the start of your marked line. Do not apply hard pressure: let the weight of the grinder and the sharp wheel do the work to avoid warping the mesh or shattering the wheel.
4. Follow the cut line: Move slowly along your marked line, cutting through each interlocking metal strand one at a time. Pause every 10–15 seconds to let the wheel and metal cool to prevent heat-related warping.
5. Smooth the edge: Once the cut is complete, run a metal file or sanding pad along the cut edge to remove sharp burrs and frayed strands.

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Method 2: Tin Snips Cut (Best for Thin, Small Projects)#

If you don’t have power tools, or you’re cutting small, irregular shapes out of thin expanded metal, aviation tin snips are a low-cost, easy-to-use alternative.

Tools Needed#

• Aviation tin snips (use straight-cut snips for straight lines, left/right offset snips for curved cuts)
• Clamps
• Straight edge
• Fine metal file
• Cut-resistant gloves and safety glasses
• Cutting oil (optional, for smoother cuts)

Step-by-Step Instructions#

1. Secure the metal: Clamp the sheet to your workbench, leaving 2–3 inches of overhang along the cut line to give you room to maneuver the snips.
2. Position the snips: Open the snips fully, and position the lower jaw of the snips on the underside of the expanded metal. This prevents bending the raised mesh strands as you cut.
3. Make consistent cuts: Squeeze the snips firmly to make small, 1–2 inch cuts along your marked line. Do not try to cut through multiple strands at once, as this will dull your blades and bend the mesh. If snips stick, apply a small drop of cutting oil to the blades.
4. Adjust for curves: For irregular or curved cuts, rotate the metal sheet as you work instead of twisting the snips, which will keep your edges clean and prevent blade damage.
5. Finish the edge: Use a fine metal file to buff away any small burrs left on the cut edge.

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Pro Tips for Perfect, Clean Cuts Every Time#

1. For long, perfectly straight cuts, clamp a metal level or straight edge along your marked line to use as a guide for your grinder or snips.
2. If cutting full 4x8 foot sheets, have a helper hold the offcut piece as you work to prevent it from falling and bending the remaining mesh or pulling on your cut line.
3. Avoid using hacksaws for expanded metal: the long, flexible blade will catch on interlocking strands, leading to jagged edges and broken blades.
4. If cutting multiple identical pieces, make a cardboard template first to trace your cut lines for consistent results.
5. For galvanized or powder-coated expanded metal, wipe the cut line with rubbing alcohol first to remove coating residue that can gunk up your grinder wheel or snips.

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Troubleshooting Common Cutting Issues#

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Final Thoughts#

Cutting expanded metal doesn’t require specialized training or expensive industrial tools. By choosing the right method for your material thickness, following basic safety rules, and taking your time, you can get clean, professional-grade cuts at home for a fraction of the cost of hiring a fabricator. Whether you’re building a new garden gate or repairing a trailer floor, these two methods will work for nearly every expanded metal project you take on.

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References#

1. Occupational Safety and Health Administration (OSHA). (2023). Personal Protective Equipment for Metal Working. Retrieved from https://www.osha.gov/metal-working/protective-equipment
2. The Fabricator. (2022). Best Practices for Cutting Expanded and Perforated Metal. Retrieved from https://www.thefabricator.com/thefabricator/article/sheetmetal/best-practices-for-cutting-expanded-and-perforated-metal
3. Popular Mechanics. (2021). Beginner’s Guide to Cutting Sheet Metal at Home. Retrieved from https://www.popularmechanics.com/home/tools/a36792059/how-to-cut-sheet-metal/