Ethan Clarke
TPI, or teeth per inch, is a crucial factor when selecting the right saw blade for cutting plastic with a jigsaw. The number of teeth per inch on a blade determines the speed and quality of the cut, with low TPI blades making rough, fast cuts and high TPI blades making slower, finer cuts. For cutting plastic, a low TPI blade is generally recommended for speed and ease of use, although the cut surface will be rougher and may require additional finishing.
| Characteristics | Values |
|---|---|
| TPI definition | Number of teeth per inch on a saw blade |
| TPI for plastic sheets | Medium TPI (18-24) for general-purpose use |
| TPI for PVC pipes and fittings | Low TPI (10-14) |
| TPI for polycarbonate sheets | Medium TPI (18-24) |
| TPI for thicker materials | Low TPI |
| TPI for softer materials | High TPI |
| TPI for harder materials | Low TPI |
| TPI for laminated materials | Down-cut blades to minimise splintering |
| TPI for non-ferrous metals | High TPI (32-64) |
| TPI for ferrous metals | Medium to high TPI (14-32) |
| TPI for acrylic sheets | High TPI (32-64) |
| TPI for plywood and veneers | Medium to high TPI (24-30) |
| TPI for wood | 6-20 |
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What You'll Learn
Plastic jigsaw blades for thicker materials
When selecting a jigsaw blade for cutting thicker plastic materials, it is important to consider the teeth per inch (TPI) of the blade. A lower TPI blade is generally recommended for thicker plastics.
For context, TPI refers to the number of teeth on a saw blade per inch. The TPI of a blade impacts the finish of the cut. A blade with a higher TPI will create finer, smoother cuts, while a blade with a lower TPI is better for rough, fast cuts.
When working with thicker plastics, a low TPI blade is ideal. Low TPI blades have fewer teeth per inch, which speeds up the cutting process and reduces the risk of clogging by removing more material with each pass. Specifically, for PVC pipes and fittings, a TPI of 10-14 is suitable, and lower TPI blades are recommended for thicker PVC materials. For polycarbonate sheets, a TPI of 18-24 is recommended as it provides a balance between cutting speed and finish quality.
In addition to TPI, other factors can influence the performance of a jigsaw blade for thicker plastics. For example, the hook angle of the blade can impact the cutting performance. Low (negative) hook angles, where the teeth angle backward, are suitable for cutting non-wood materials such as plastics. By selecting an appropriate hook angle and TPI, you can achieve the desired finish on thicker plastic materials.
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Plastic jigsaw blades for softer materials
When selecting the right jigsaw blade for softer plastics, several factors come into play, including the type of blade, the number of teeth per inch (TPI), and the desired finish.
First and foremost, it is crucial to choose a blade that is specifically designed for cutting softer plastics. The most common types of blades for this purpose are made from high-speed steel (HSS) or tungsten carbide. HSS blades are suitable for softer plastics and can also be used for cutting harder materials such as metal and aluminium. On the other hand, tungsten carbide blades are recommended for very hard plastics, such as fibre-reinforced plastic, and they offer a longer service life than standard blades.
The TPI of the blade plays a significant role in the cutting process. For softer plastics, a lower TPI blade is generally recommended. Blades with 10-14 TPI are suitable for thicker plastics, as they have fewer teeth per inch, resulting in faster and rougher cuts. This range of TPI is commonly used for PVC pipes and fittings, where speed and efficiency are important.
However, if you require a balance between cutting speed and finish quality, a medium TPI blade is a better choice. Blades with 18-24 TPI can handle a wide range of materials, from thin to thick. They provide good control and relatively clean cuts, making them versatile and suitable for everyday tasks. This TPI range is often used for polycarbonate sheets, where a smoother finish is desired without sacrificing cutting speed.
It is worth noting that the ideal TPI and cutting tool can vary depending on specific requirements, such as material thickness and the desired finish. While TPI is a crucial factor, other considerations, such as tooth shape and angle, also come into play when selecting the right blade for your project. For example, low (negative) hook angles, where the teeth angle backward, are suitable for cutting non-wood materials like plastics. Additionally, the desired finish, whether a rough cut or a fine cut, will influence the choice of blade.
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Blade types for plastic jigsaws
When selecting a jigsaw blade for cutting plastic, it is important to consider the type of plastic being cut, the desired cut quality, and the blade compatibility with your jigsaw.
For softer plastics, High Carbon Steel (HCS) blades are a good option. HCS blades are flexible and can withstand bends, making them suitable for curved cuts. They are also inexpensive and commonly used for light-duty plastics. However, the teeth on HCS blades may wear out faster when used on tougher materials. When using an HCS blade, a tooth count of 6-10 TPI is recommended for a faster cut speed, although this may result in a rougher edge. For smoother cuts, a higher TPI is suggested.
Tungsten Carbide (TC) blades are recommended for cutting harder plastics, such as fibre-reinforced plastic. TC blades are extremely hard and durable, providing a longer service life than standard blades. They are commonly used for industrial applications and can cut through abrasive materials. When using TC blades, it is important to adjust the jigsaw speed to medium and switch off the orbital (pendulum) action to avoid generating excessive heat and melting the plastic.
Additionally, when cutting plastics, it is crucial to ensure that the jigsaw blade is compatible with your specific jigsaw model. Older jigsaws may require U-shank blades, while newer jigsaws typically use T-shank blades that offer a wider variety of options.
When selecting a jigsaw blade, it is important to refer to the manufacturer's recommendations and consider factors such as cut quality, speed, and the type of plastic being cut to make an informed decision.
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Tooth shape and angle for plastic jigsaws
When cutting plastic jigsaw pieces, the number of teeth per inch (TPI) on the blade will depend on the type of plastic and the desired finish. For PVC pipes and fittings, a TPI of 10-14 is suitable, while thicker PVC materials are best cut with lower TPI blades. Polycarbonate sheets typically require a TPI between 18 and 24.
The tooth shape and angle of a blade can also impact the finish of the cut. Here are some key factors to consider:
- Rake: The rake of a tooth refers to the angle of the cutting face. A 0-degree rake creates a very aggressive cut, while increasing the angle makes the saw easier to push and control but may slow down the cutting process.
- Fleam: Fleam is the angle across the face of the tooth or perpendicular to the tooth line. Adding fleam turns the teeth into slicing knives, resulting in cleaner cuts but weaker teeth. High fleam saws are best for softer woods, while low fleam saws are used for harder woods.
- Set: The set is the amount of offset of the teeth to either side of the tooth line. Setting the teeth creates a wider kerf, allowing the saw to run without binding.
- Ground: A ground design creates a sharp edge with straight teeth alignment, resulting in fine, sharp, and clean cuts.
- Ground Side Set: This design cuts according to the oblique angle of the teeth and is ideal for cutting wood at high speed.
- Hook Angle: The direction of the blade's teeth, or hook angle, also affects the cut. Higher hook angles create more aggressive cuts, while low (negative) hook angles are good for crosscutting and cutting non-wood materials like plastics and metals.
- Alternate Top Bevel: This tooth design is bevelled on the top, with adjacent teeth bevelled in opposite directions. These blades are easy to re-sharpen and ideal for cross-cutting solid woods and veneered plywood.
When choosing a blade for cutting plastic jigsaw pieces, consider the thickness of the material and the desired finish. Lower TPI blades are typically used for thicker plastics, while medium TPI blades (18-24 TPI) provide a good balance between cutting speed and finish quality.
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Finish type for plastic jigsaws
When it comes to finish types for plastic jigsaws, there are a variety of options available, each serving a specific purpose. The finish of a plastic product is crucial in achieving the desired aesthetic and functionality. Here is an overview of the different finish types:
Mirror Finish (A-1 Grade)
The A-1 grade finish is characterised by its high level of shine and reflectiveness. This finish is achieved using diamond powder suspended in an oil solution, resulting in a mirror-like surface. It is commonly used for plastic mirrors or other optical parts where a clear and undistorted reflection is required.
Semi-Gloss Finishes (B-1, B-2, and B-3 Grades)
Semi-gloss finishes offer a balance between shine and matte, providing a smooth surface without the high gloss of a shiny finish. These finishes are created using different types of grit paper and are suitable for a variety of applications, including product exteriors and parts that require a smoother finish.
Matte and Dull Finishes (C Grades)
Matte and dull finishes are typically used for diecast and thermoset parts. They are created using fine stone powder and can be achieved through processes like sandblasting. These finishes range from satin to dull, providing a subtle and understated look.
Rough and Unpolished Finishes
These finishes are generally used for internal parts or products that do not require a high level of shine. They are the least polished grades and are often a result of the plastic injection moulding process. The choice of finish depends on the intended use of the product, emphasising the importance of understanding the product's purpose before finalisation.
It is worth noting that the finish type may also be influenced by the type of jigsaw blade used. For cutting plastic, a blade with a higher tooth count is recommended, resulting in a slower cut speed but a smoother finish. Additionally, when using a jigsaw to cut plastic, it is important to use a specialised blade designed for plastic, such as those identified by a red shank in Bosch jigsaws.
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Frequently asked questions
TPI stands for teeth per inch.
A low TPI blade is ideal for cutting plastic as it makes rough, fast cuts. A medium TPI blade can also be used for cutting plastic and will provide a balance between cutting speed and finish quality.
Low TPI blades have fewer teeth per inch, making them ideal for rough, fast cuts.
Medium TPI blades are a great choice for general-purpose use as they can handle a variety of materials, thick and thin. They offer a good mix of speed and finish quality.
For cutting wood, a blade with a TPI of 6 up to 20 is recommended.
