Cutting Techniques Across Material Categories

This lesson covers the cutting techniques used for different material categories, as required by AQA GCSE D&T (8552), Section 3.2.5. Cutting is usually the first step in making any product — converting raw stock material into the required size and shape. Different materials require different cutting tools and techniques, and choosing the correct method is essential for accuracy, safety, and quality.

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Cutting Timber and Manufactured Boards

Hand Tools for Cutting Timber

Tool	Description	Best For	Teeth
Tenon saw	Short, stiff blade with a brass or steel spine for rigidity	Straight cuts in wood joints (tenons, shoulders); cutting to a marked line	Fine teeth (12-14 TPI); crosscut and rip
Coping saw	Thin blade held in a U-shaped frame; blade can be rotated	Cutting curves and intricate internal shapes in thin timber and manufactured boards	Very fine teeth; can cut in any direction
Hand saw (panel saw)	Long, flexible blade without a spine	Cutting large pieces of timber and sheet material to rough size	Medium teeth (8-10 TPI)
Fret saw	Similar to coping saw but with a deeper throat	Very intricate curved cuts in thin materials; greater reach than a coping saw	Very fine teeth

Machine and Power Tools for Cutting Timber

Tool	Description	Best For	Key Safety
Band saw	Continuous loop blade running over two wheels; table-mounted	Cutting curves in thick timber; resawing boards	Guards must cover the unused blade; hands must stay well clear
Scroll saw	Reciprocating blade mounted in a table; for very fine work	Intricate internal and external cuts in thin timber and MDF	Low risk — blade is short and slow; still requires guard
Circular saw (table saw)	Spinning disc blade mounted in a table	Straight rip cuts along the grain; cross cuts in sheet material	Crown guard, riving knife, push sticks — high risk tool
Laser cutter	Focused CO2 laser beam cuts or engraves material	Highly precise, intricate cuts in MDF, plywood, acrylic	Enclosed cabinet; fume extraction essential; never leave unattended
CNC router	Computer-controlled spinning cutting tool	Complex 2D and 3D shapes in timber and manufactured boards	Enclosed or guarded; ear protection; dust extraction

AQA Exam Tip: When describing a cutting process in the exam, name the specific tool (not just "a saw"), explain why it is suitable for the specific material and shape, and mention at least one safety precaution. This level of detail is what separates good answers from excellent ones.

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Cutting Metals

Hand Tools for Cutting Metal

Tool	Description	Best For
Hacksaw	Rigid frame holding a replaceable blade	Cutting metal bar, rod, tube, and sheet to size; general-purpose metal cutting
Junior hacksaw	Small hacksaw for lighter work	Cutting small metal sections, wire, thin tube
Tin snips (aviation snips)	Compound-lever hand shears	Cutting thin sheet metal (up to ~1.2 mm mild steel, thicker aluminium)
Files	Hardened steel bars with rows of cutting teeth	Removing material to shape, smooth, or deburr cut edges

Machine and Power Tools for Cutting Metal