How to Cut Plywood On Table Saw: Achieve Clean Cuts

Can you cut plywood on a table saw? Yes, you can! Cutting plywood on a table saw is a common woodworking task, but achieving clean, splinter-free cuts requires the right tools, techniques, and a healthy dose of caution. This guide will walk you through everything you need to know to master table saw plywood cutting techniques, from selecting the best blade to implementing effective methods for preventing tearout.

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Essential Tools and Preparation

Before you start cutting, make sure you have the right tools and have prepped your plywood.

Required Equipment

• Table Saw: A stable and well-maintained table saw is crucial.
• Best Blade for Plywood Table Saw: A high-tooth-count blade designed for plywood is essential. More on this below.
• Safety Glasses: Protect your eyes from flying debris.
• Hearing Protection: Table saws can be loud; protect your hearing.
• Push Stick/Push Block: Use these to keep your hands safely away from the blade.
• Featherboards (Optional): These help keep the plywood snug against the fence.
• Clamps: For securing jigs or workpieces.
• Measuring Tools: A good tape measure and square are a must.
• Dust Collection: Hook up a shop vac to your table saw to minimize dust.

Plywood Preparation

1. Inspect the Plywood: Look for any warps, bends, or loose veneers. These can affect the quality of your cut.
2. Mark Your Cut Lines: Use a sharp pencil or marking knife for precise lines. Ensure the lines are clear and easy to follow.
3. Support the Plywood: Large sheets of plywood can be unwieldy. Use outfeed supports or roller stands to keep the plywood stable.

Selecting the Right Table Saw Blade for Clean Plywood Cuts

The key to splinter-free plywood table saw cuts lies in choosing the right blade.

Tooth Count and Grind

• High Tooth Count: Blades with 60 to 80 teeth are ideal for plywood. More teeth result in a smoother cut.
• ATB (Alternate Top Bevel) Grind: This grind is common for plywood blades. The alternating bevels slice through the wood fibers cleanly.
• Hi-AT (High Alternate Top Bevel) Grind: Offers an even cleaner cut but can be more expensive.

Blade Quality

• Carbide-Tipped Blades: Carbide tips stay sharp longer than steel blades. This is essential when working with plywood, which can quickly dull a blade.
• Thin-Kerf Blades: These blades remove less material, reducing the load on your saw and minimizing tearout.

Recommended Blades

Blade Type	Tooth Count	Grind	Application
Fine Finish Plywood Blade	80	ATB	Splinter-free cuts on thin plywood
Combination Blade	50	ATB	Ripping and crosscutting thicker ply
Thin Kerf Blade	40-60	ATB	Reduced tearout and easier feeding

Table Saw Plywood Cutting Techniques: Ripping and Crosscutting

There are two main types of cuts you’ll make on plywood: ripping and crosscutting.

Ripping Plywood on Table Saw

Ripping is cutting plywood along the grain.

1. Set the Fence: Measure the distance from the blade to the fence and set the fence accordingly. Double-check your measurement.
2. Feed the Plywood: Keep the plywood flat on the table and push it steadily along the fence. Use a push stick to guide the plywood near the blade and keep your hands safely away.
3. Maintain Consistent Speed: A consistent feed rate helps prevent burning and tearout.

Crosscutting Plywood on Table Saw

Crosscutting is cutting plywood against the grain. This requires more care to prevent tearout.

1. Use a Miter Gauge: Set the miter gauge to the desired angle (usually 90 degrees for square cuts).
2. Support the Plywood: Keep the plywood flat against the miter gauge and the table. Use an extension wing on your miter gauge for better support if possible.
3. Slow and Steady: Push the miter gauge forward at a slow, controlled pace. Avoid stopping mid-cut.

Preventing Tearout Plywood Table Saw

Tearout is the bane of plywood cutting. Here are several techniques to minimize it.

Scoring Cut

• The Method: Before making the final cut, raise the blade just slightly above the table (about 1/8 inch). Make a shallow scoring cut along the cut line. This helps sever the surface fibers, preventing them from tearing out during the final cut.
• Benefits: Very effective for preventing tearout on the top surface of the plywood.

Painter’s Tape

• The Method: Apply painter’s tape along the cut line on both sides of the plywood. The tape helps hold the wood fibers together.
• Benefits: Simple and relatively effective, especially for small projects.

Zero-Clearance Insert

• The Method: A zero-clearance insert fits tightly around the blade, eliminating the gap between the blade and the table. This provides support to the wood fibers right next to the blade.
• Benefits: Significantly reduces tearout on the bottom surface of the plywood. You can buy pre-made zero-clearance inserts or make your own.

Backer Board

• The Method: Clamp a piece of scrap wood (the backer board) tightly against the back of the plywood. The backer board provides support and prevents tearout as the blade exits the plywood.
• Benefits: Works well for crosscuts, especially when using a miter saw or a sled on the table saw.

Climb Cutting (Use with Extreme Caution)

• The Method: Climb cutting involves feeding the plywood against the rotation of the blade. This can produce a very clean cut, but it’s also extremely dangerous because it can cause the plywood to be thrown back at you.
• Benefits: Can produce a very clean cut with minimal tearout.
• Risks: High risk of kickback. Only attempt this if you are very experienced and have excellent control of the plywood. Use featherboards and a firm grip.

Accurate Plywood Cuts Table Saw

Accuracy is crucial for any woodworking project.

Precise Measurements

• Double-Check: Always double-check your measurements before cutting.
• Sharp Tools: Use a sharp pencil or marking knife for precise lines.
• Consistent Reference: Always measure from the same edge of the plywood.

Fence and Miter Gauge Setup

• Parallel Fence: Ensure your table saw fence is parallel to the blade. An improperly aligned fence can lead to inaccurate cuts and binding.
• Square Miter Gauge: Verify that your miter gauge is square to the blade. Use a reliable square to check the angle.

Using Jigs for Repeatable Cuts

• Construction: Build a simple jig to hold the plywood at a specific angle or distance from the blade.
• Benefits: Ensures consistent and repeatable cuts, especially for angled pieces.

Plywood Cutting Jig Table Saw

A plywood cutting jig table saw can greatly enhance accuracy and safety. Here are a couple of common jig types.

Crosscut Sled

• Construction: A crosscut sled consists of a large platform that slides in the miter slots of your table saw. A fence is attached to the platform at a 90-degree angle to the blade.
• Benefits: Provides excellent support for crosscutting plywood. It also makes it easy to cut precise angles.

Tapering Jig

• Construction: A tapering jig allows you to cut angled tapers on plywood. It typically consists of a base with an adjustable fence that can be set at the desired angle.
• Benefits: Ideal for creating tapered legs for furniture or other projects requiring precise angles.

Safe Plywood Cutting on Table Saw

Safety should always be your top priority.

Personal Protective Equipment (PPE)

• Safety Glasses: Protect your eyes from flying debris.
• Hearing Protection: Table saws are loud.
• Dust Mask: Plywood dust can be harmful to your lungs.

Safe Practices

• Keep Your Hands Away: Always use push sticks or push blocks to keep your hands a safe distance from the blade.
• Avoid Reaching Over the Blade: Never reach over the blade while the saw is running.
• Stay Focused: Avoid distractions while operating the table saw.
• Maintain Control: Keep a firm grip on the plywood and feed it steadily.
• Be Aware of Kickback: Kickback occurs when the plywood is thrown back at you by the blade. To prevent kickback, use a riving knife or splitter, and avoid forcing the plywood through the blade.

Maintaining Your Table Saw

• Sharp Blade: A sharp blade cuts more cleanly and is less likely to cause kickback.
• Cleanliness: Keep your table saw clean and free of dust and debris.
• Proper Adjustment: Ensure all parts of your table saw are properly adjusted and tightened.

Splinter-Free Plywood Table Saw: Optimizing for Best Results

Combining the techniques above will give you the best chance at achieving splinter-free cuts.

1. Use a High-Quality Blade: Invest in a blade specifically designed for plywood with a high tooth count and an ATB grind.
2. Implement Tearout Prevention: Employ a combination of scoring cuts, painter’s tape, and a zero-clearance insert.
3. Maintain Proper Feed Rate: A slow, steady feed rate is crucial for preventing tearout.
4. Support the Plywood: Use outfeed supports and roller stands to keep the plywood stable.
5. Regularly Inspect and Maintain Your Equipment: Keep your blade sharp, your fence parallel, and your miter gauge square.

Troubleshooting Common Issues

• Tearout Still Occurring: Check your blade sharpness, try using a backer board, and reduce your feed rate.
• Burning: A dull blade or a feed rate that is too slow can cause burning.
• Inaccurate Cuts: Double-check your measurements and ensure your fence and miter gauge are properly adjusted.

Fathoming Different Types of Plywood

Different types of plywood require slightly different approaches.

Plywood Type	Characteristics	Cutting Considerations
Hardwood Plywood	Durable, smooth surface, often used for furniture	Requires a sharp blade and careful attention to tearout prevention.
Softwood Plywood	Less expensive, often used for construction	Can be more prone to tearout. Use a scoring cut and a high-tooth-count blade.
Marine Plywood	Water-resistant, used for boat building	Similar to hardwood plywood; use a sharp blade and prevent tearout.
MDF Core Plywood	Flat and stable, often used for cabinetmaking.	Prone to tearout; use a zero-clearance insert and a scoring cut.

FAQ: Plywood and Table Saws

What is the best way to prevent tearout when cutting plywood?
The best way to prevent tearout is to use a combination of techniques, including a high-tooth-count blade, a scoring cut, painter’s tape, and a zero-clearance insert.

Can I use a regular blade to cut plywood?
While you can use a regular blade, it’s not recommended. A blade designed for plywood will produce much cleaner cuts with less tearout.

Who is responsible if I get injured using a table saw?
Ultimately, you are responsible for your own safety. Following safe practices and using appropriate safety equipment is crucial.

Is it better to rip or crosscut plywood first?
Generally, it’s best to rip plywood first, then crosscut. Ripping larger pieces is often easier to manage.

What is a zero-clearance insert and why is it important?
A zero-clearance insert is a table saw insert that fits tightly around the blade. It provides support to the wood fibers right next to the blade, significantly reducing tearout.

Can I cut plywood without a table saw?
Yes, you can use a circular saw, jigsaw, or hand saw. However, a table saw generally provides the most accurate and efficient cuts for larger projects.

Mastering table saw plywood cutting techniques is a skill that will serve you well in any woodworking endeavor. By following these guidelines, you can achieve clean, accurate, and safe plywood cuts every time.