Tubes and Pipes are suitable industrial products that can be made from different materials of different flexibility and density for plumbing systems such as copper, galvanized steel, aluminum and cast iron. Many factors involve choosing the particular technique or technology to cut the product for tubes and pipes fabrication. The process’s primary factors are the tubes and pipes material, the squareness of ends, wall thickness, end conditioning requirements and secondary process needs. Other features that affect the cutting procedure include production volume, overhead costs, cutting efficiency and unique requirements.

Before Cutting Tubes and Pipes

Before getting to the introduction of the most practical tubes and pipes cutting methods, experts should consider initial steps to ensure the quality of the process. The followings are essential steps before starting the cutting procedure:

  • Regardless of the material, it is necessary to measure the diameter of the product to be cut to ensure that the operator utilizes the suitable size cutter for the job.
  • For determining a line for a straight cut, it is appropriate to use a tape measure and a pencil or other writing instruments to mark on the surface of the product. It is better to mark around the product’s circumference, especially when the cutting tool is a handsaw.
  • By securing the pipe and tube with a clamp, miter box or even duct tape, it is possible to ensure the cut as straight as possible, and this way, the operator can keep the length from slipping out of place during the cutting process.

Abrasive Cutting

This cutting method is a basic, manual technique for cutting-to-length product to the customers demanding in any alloy. The process operates by utilizing a circular abrasive blade or a wheel with resin composition to grind through the product. The cut size of the fabrication depends entirely on the device. This particular system is suitable for small product runs that do not need end conditions.

Band Saw Tubes and Pipes Cutting

This cutting method is a fully automated process, and most manufacturers utilize the system to cut rods, bars, pipes and tubes. The band saw way is perfect for large volume production. The blade used in this system is a continuous band of metal material with various tooth configurations that rotates on two wheels. The blade approach can be horizontal and vertical depending on the demanding design. Each format has its unique advantages for particular projects. However, this method is not an efficient process for fabricating thin-walled products, and it can produce burr and will not achieve a stable threshold.

Cold Sawing

The cold sawing method is famous for its precision in cutting smaller diameter or thin-walled material with tight tolerance using a wheel blade and cutting fluid applied with a film lubricator. The cutting tool in the cold saw system is fixed and does not have movement with which manufacturers can create square or perpendicular cuts with minimal or no burrs. This precise cutting system can bundle cut products with small length tolerance. The cold cutting process does not produce HAZ, which is considered an advantage for a material that requires subsequent finishing.

Cutting Tubes and Pipes with Laser Cut

The modern laser cutting method provides a range of advantages despite its high cost. This system can be controlled easily with CNC or other automation devices, and it allows the operator to inspect and cut the material. At the same time, the laser beams run continuously on the surface. Utilizing the laser cut method makes it possible to fabricate more rigid materials, including stainless steel alloys, titanium, and nickel alloys. However, this particular method is also used to manufacture other industrial materials such as aluminum composite panels.


The shearing method utilizes a particular automatic and high-speed machine that features two shearing plates and two punches under extreme pressure to complete the fabricating process. The process is done in the same way for all sizes and wall thicknesses with almost maximum limits. The primary advantages of shearing technology are its speed and volume. Due to the high output rate of this operation, it can create about 7,000 pieces per hour, and the specific abilities depend on the material’s wall thickness and shear.

Lathe Cutting

The single-spindle lathe machines are used to provide high-volume production and cutting of round tubes and pipes. The operator needs to feed the material through the spindle and gauge the cut length. A collet holds the stock and rotates it to start the cutting with mounted tools. Using a cooling liquid is essential to control the temperature and reduce the tool wear for preventing further damages. It is good to note that this technique is efficient for thin-walled material to produce square cuts with a minimum bur. One of the vital advantages of this method is high production yield while setup time ranges from thirty minutes to an hour.