Metal Shears

About Metal Shears

Metal shears are essential cutting tools designed specifically for cleanly slicing through sheet metal, tin, aluminium, and other thin metal materials without deformation. Unlike general-purpose scissors or snips, metal shears feature robust forged or hardened steel blades with precise cutting angles that deliver clean, burr-free edges on materials up to several millimetres thick. Available in various configurations including straight-cut, left-cut, and right-cut models, these tools enable accurate cutting in both straight lines and curves, making them indispensable for metalworking tasks ranging from roofing and cladding to automotive fabrication and HVAC installation.

The selection at Tooled-Up.com includes hand-operated aviation snips for portable cutting tasks, bench-mounted disc cutters for workshop applications, and specialist chamfer shears for creating angled edges. Quality metal shears typically feature ergonomic handles—often with PVC or cushioned grips—to reduce hand fatigue during extended use, whilst premium models incorporate titanium coatings or compound leverage mechanisms that significantly reduce the force required to cut through tougher materials. Professional-grade shears from brands such as Expert by Facom, Stanley, and Sealey offer cutting capacities suitable for stainless steel up to 0.8mm and mild steel up to 1mm thickness, with blade lengths typically ranging from 40mm to 60mm.

Modern metal shears have evolved considerably from traditional tinsnips, with enhanced durability, precision-ground cutting edges, and improved leverage systems that make cutting metal sheet less physically demanding. Many contemporary models feature colour-coded handles to instantly identify cutting direction—a crucial detail when working with complex patterns or tight curves where the wrong shear orientation can ruin a workpiece.

Jargon Buster

• Straight-Cut Shears: Metal shears designed with blades configured for cutting in straight lines or gentle curves. The most versatile type for general sheet metal work, suitable for approximately 80% of typical cutting tasks.
• Aviation Snips: Compact, spring-loaded metal shears originally developed for aircraft construction. Available in left-cut (red handles), right-cut (green handles), and straight-cut (yellow handles) variants, these tools excel at intricate cutting work.
• Cutting Capacity: The maximum thickness of material a particular shear can cut, usually specified separately for different materials (e.g., stainless steel, mild steel, aluminium). Typically measured in millimetres and varies according to material hardness.
• Compound Action: A leverage mechanism that multiplies cutting force through a double-pivot system, enabling easier cutting of thicker or harder materials with less hand pressure required from the operator.
• Chamfer Shears: Specialised metal shears featuring one narrow and one wide blade, designed specifically for creating bevelled or angled edges on sheet metal, commonly used in flashing and ductwork fabrication.
• Burr: The rough or sharp edge that can form along the cut line when metal is sheared. Quality shears minimise burring, reducing the need for subsequent filing or deburring operations.

Who Uses Metal Shears?

• Roofers and Cladders: Cutting flashing, guttering, ridge caps, and metal roofing sheets to precise dimensions on site
• HVAC Engineers: Fabricating and fitting ductwork, ventilation components, and metal enclosures for heating and cooling systems
• Sheet Metal Fabricators: Creating bespoke metalwork, enclosures, panels, and architectural metalwork in workshop environments
• Plumbers: Cutting metal strapping, brackets, and occasionally thin copper or aluminium sheet for custom applications
• Automotive Body Technicians: Trimming repair panels, patches, and custom metalwork during vehicle restoration and modification
• Electricians: Cutting metal trunking, cable trays, and enclosure panels to fit specific installation requirements
• Maintenance Engineers: General repairs and modifications involving sheet metal components in industrial and commercial settings
• Hobbyists and Model Makers: Precision cutting of thin metal sheet for crafts, scale models, and artistic metalwork projects

How to Choose the Right Metal Shears

Material and Thickness: Identify the types and gauges of metal you'll be cutting most frequently. If working primarily with stainless steel or harder materials, invest in shears with higher cutting capacity ratings (typically 0.8mm for stainless, 1mm for mild steel). For occasional light-duty work, standard models will suffice, whilst professionals cutting harder materials daily should consider premium options with titanium-coated blades for extended edge retention.

Cutting Direction: Straight-cut shears handle most general applications, but if your work involves intricate curves or requires keeping waste material flat whilst cutting, dedicated left-cut or right-cut aviation snips prove invaluable. Right-handed users typically find left-cut shears (cutting clockwise curves) and right-cut shears (anticlockwise curves) more comfortable, with the waste curling away from the cutting line.

Handle Design and Ergonomics: Extended cutting sessions demand comfortable, well-designed handles. Look for PVC-sheathed or cushioned grips that distribute pressure across the palm, and consider spring-loaded models that automatically reopen the blades, reducing repetitive strain. Handle length affects leverage—longer handles provide more cutting force but reduce manoeuvrability in confined spaces.

Blade Length and Configuration: Blade lengths between 40mm and 50mm offer the best balance of cutting speed and control for most applications. Chamfer shears with asymmetric blades suit specialist bevelling work, whilst universal shears with symmetric blades handle the broadest range of tasks. Forged carbon steel blades outlast stamped alternatives and maintain sharper edges through prolonged use.

Bench-Mounted vs Handheld: Workshop-based metalworkers benefit from bench-mounted disc cutters available from Tooled-Up, which provide greater cutting capacity and consistency for repetitive operations. However, handheld shears remain essential for site work, offering portability and versatility that stationary equipment cannot match.

Popular Accessories

• Cutting Lubricants: Specialist fluids that reduce friction and heat buildup, extending blade life and improving cut quality on thicker materials
• Replacement Blades: Spare cutting edges for models with user-replaceable blade systems, ensuring uninterrupted productivity
• Sharpening Stones and Files: For maintaining optimal cutting edges on shears between professional sharpening services
• Metal Scribes and Marking Tools: For accurately marking cutting lines before shearing, ensuring precision cuts
• Bench Vices: Essential for securing workpieces when using handheld shears on thicker materials requiring greater force
• Deburring Tools: For removing sharp edges and burrs left after cutting, creating safe, professional-quality edges
• Tool Holsters and Storage: Protecting shear blades during transport and keeping frequently-used cutting tools readily accessible on site
• Safety Gloves: Cut-resistant gloves protecting hands from sharp metal edges whilst maintaining dexterity for precision work

Safety Information

Personal Protective Equipment: Always wear appropriate safety glasses or goggles when cutting metal, as small fragments and slivers can become airborne projectiles. Cut-resistant gloves protect against sharp edges on both the workpiece and freshly cut material, though ensure gloves fit properly to maintain control and prevent entanglement. Long sleeves provide additional protection against sharp edges and metal fragments.

Cutting Technique: Maintain firm control of both the shears and workpiece throughout the cutting operation. Position material securely—ideally clamped in a vice for thicker stock—to prevent unexpected movement that could cause the shears to slip. Keep fingers and hands clear of the cutting line, and ensure adequate clearance for waste material which may curl or spring away from the cut.

Tool Maintenance: Keep blades sharp and properly aligned; dull shears require excessive force that increases fatigue and the risk of loss of control. Inspect shears before use for loose fasteners, damaged handles, or blade misalignment. Clean blades after use to prevent corrosion, particularly when cutting galvanised or treated metals that leave corrosive residues.

Work Environment: Ensure adequate lighting to clearly see cutting lines and potential hazards. Maintain a clutter-free work area, as offcuts and metal fragments create trip hazards and puncture risks. When using bench-mounted disc cutters, ensure the equipment is securely fastened and guards are properly positioned before operation, in accordance with HSE guidance on metalworking machinery.

Frequently Asked Questions

What's the difference between tin snips and aviation snips?

Tin snips are traditional straight-cutting tools with simple pivot mechanisms, whilst aviation snips (compound-action snips) feature enhanced leverage systems that reduce required cutting force by up to 40%. Aviation snips are available in three colour-coded types: straight-cut (yellow), left-cut (red), and right-cut (green). The compound action and directional specialisation make aviation snips significantly more versatile and less fatiguing for professional use, though quality tin snips remain perfectly adequate for occasional light-duty applications.

Can I cut stainless steel with standard metal shears?

This depends on the shears' specified cutting capacity and the stainless steel thickness. Quality metal shears explicitly rated for stainless steel—such as those from Expert by Facom stocked at Tooled-Up.com—typically handle stainless up to 0.8mm thickness. Attempting to cut stainless steel exceeding the manufacturer's specifications will damage blade edges, potentially void warranties, and create dangerous situations where shears might slip under excessive force. Always verify cutting capacity ratings before purchasing if stainless steel work is anticipated.

How do I prevent the metal from deforming whilst cutting?

Support the workpiece adequately on both sides of the cutting line, ideally clamping larger sheets to a workbench. Use long, smooth cutting strokes rather than short, choppy cuts which create distortion. Ensure blades are sharp—dull edges crush and deform metal rather than cleanly shearing it. When cutting curves, use the appropriate directional aviation snip (left-cut or right-cut) so waste material curls away from the cutting line rather than underneath it, which causes buckling and distortion.

Do metal shears need sharpening, and can I do this myself?

Yes, metal shears require periodic sharpening to maintain optimal performance. Whilst professional sharpening services provide the best results and proper blade geometry, experienced users can perform basic edge maintenance using fine-grit sharpening stones or files. Work carefully along the existing bevel angle, maintaining consistent pressure and angle throughout. However, improper sharpening can permanently damage blades, so when in doubt, consult the manufacturer's guidance or use professional sharpening services, particularly for premium shears.

What thickness of mild steel can typical metal shears cut?

Professional-quality metal shears generally cut mild steel up to 1mm thickness, whilst heavy-duty models may extend to 1.2mm. However, cutting capacity varies significantly between manufacturers and models. The shears available from brands like Sealey and Stanley typically specify separate cutting capacities for different materials—mild steel, stainless steel, and aluminium—as material hardness dramatically affects cutting performance. Always verify specifications for your intended materials rather than assuming equivalent performance across different metal types.