How To Cut Plywood With A Table Saw: Tips For Clean Cuts

Do you want to know how to cut plywood with a table saw? Yes, it’s a great way to cut plywood. This guide provides tips and tricks for achieving clean, professional results, including selecting the right blade, preventing tearout, and ensuring safety. Read on to learn about plywood cutting techniques.

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The Right Tools & Setup for Plywood Success

Before you even think about pushing that plywood through your table saw, you need to get your ducks in a row. This involves having the right tools, setting them up correctly, and prioritizing safety. Let’s break down each element.

Selecting the Best Table Saw Blade for Plywood

Choosing the correct blade is the most crucial step in achieving clean cuts on plywood. Plywood is notorious for splintering, so a blade designed to minimize tearout is essential.

• High Tooth Count Blades: Blades with 60-80 teeth are ideal for plywood. More teeth equal a cleaner cut. These blades are often labeled as “plywood blades” or “fine-tooth blades.”
• Alternate Top Bevel (ATB) Grind: This grind pattern features teeth that alternate beveled edges, slicing the wood fibers cleanly. ATB blades are commonly used for plywood and hardwoods.
• Triple Chip Grind (TCG): While primarily for non-ferrous metals and plastics, TCG blades can also provide clean cuts on plywood. They are particularly useful for thicker plywood.
• Negative Hook Angle: A negative hook angle pushes the wood down into the table, helping to prevent lifting and splintering. This is a great feature for plywood blades.

Here’s a table summarizing blade recommendations:

Blade Type	Tooth Count	Grind Type	Hook Angle	Best For
Plywood Blade	60-80	ATB	Negative	Thin to Medium Plywood, Clean Cuts
Fine-Tooth Blade	60-80	ATB	Positive	Thin Plywood, General Purpose
Combination Blade	40-50	ATB	Positive	Ripping and Crosscutting (Acceptable Results)
Triple Chip Grind (TCG)	40-60	TCG	Neutral	Thick Plywood, Laminates

Setting Up Your Table Saw for Plywood

Once you have the right blade, proper setup is paramount.

• Blade Height: Raise the blade so that the teeth extend just above the plywood. Exposing too much blade increases the risk of tearout and kickback. Generally, a blade height of about ¼ inch above the material is sufficient.
• Zero Clearance Insert: A zero clearance insert supports the wood fibers right up to the blade, preventing splintering on the underside of the cut. You can buy pre-made inserts or make your own.
• Fence Alignment: Ensure your fence is perfectly parallel to the blade. Misalignment can cause binding, kickback, and inaccurate cuts. Use a reliable measuring tool to check the distance between the fence and the blade at both the front and back.
• Dust Collection: Plywood creates a lot of fine dust, which is harmful to breathe and reduces visibility. Connect your table saw to a dust collector or shop vacuum.

Table Saw Safety When Cutting Plywood

Table saws are powerful tools, and safety should always be your top priority. Follow these safety guidelines:

• Wear Safety Glasses: Always wear safety glasses to protect your eyes from flying debris.
• Use Push Sticks/Paddles: Never put your hands close to the blade. Use push sticks or paddles to guide the plywood through the cut, especially when ripping narrow pieces.
• Anti-Kickback Devices: Make sure your table saw’s anti-kickback pawls and riving knife are properly installed and adjusted. These devices help prevent the workpiece from being thrown back towards you.
• Stay Focused: Avoid distractions and maintain your concentration while operating the table saw.
• Proper Stance: Stand to the side of the blade’s cutting path, not directly behind it, to avoid being hit by kickback.
• Inspect Plywood: Before cutting, inspect the plywood for any loose knots, screws, or nails. These can damage the blade and cause dangerous projectiles.
• Avoid Reaching Over the Blade: If you need to adjust the plywood during a cut, stop the saw completely and wait for the blade to stop spinning.

Mastering Plywood Cutting Techniques

Now that you’re equipped with the right tools and a safe setup, let’s dive into specific plywood cutting techniques for achieving clean cuts.

Ripping Plywood on a Table Saw

Ripping refers to cutting plywood along the grain. Here’s how to do it effectively:

1. Measure and Mark: Accurately measure and mark the plywood according to your desired dimensions. Use a sharp pencil or marking knife for precision.
2. Set the Fence: Adjust the table saw fence to the correct width. Double-check the measurement to ensure accuracy.
3. Support the Plywood: Use outfeed supports or a helper to support the plywood as it exits the saw. This prevents the plywood from sagging and causing tearout.
4. Feed at a Consistent Rate: Feed the plywood through the saw at a steady, controlled pace. Avoid stopping or hesitating mid-cut, as this can cause burning or splintering.
5. Use a Push Stick: Use a push stick to guide the plywood along the fence, keeping your hands safely away from the blade.
6. Manage Offcuts: Be mindful of the offcut piece, especially when ripping narrow strips. It can sometimes get caught between the blade and the fence, leading to kickback.

Crosscutting Plywood on a Table Saw

Crosscutting involves cutting plywood against the grain. It typically requires a different approach than ripping.

1. Use a Miter Gauge or Crosscut Sled: A miter gauge or crosscut sled provides a stable platform for crosscutting plywood accurately and safely. A crosscut sled is generally preferred for larger pieces as it offers greater support.
2. Secure the Plywood: Ensure the plywood is firmly against the miter gauge or crosscut sled. Use clamps if necessary.
3. Slow and Steady: Push the miter gauge or sled slowly and steadily through the blade. Avoid forcing the cut.
4. Support the Plywood: Support the plywood on both sides of the blade to prevent sagging.
5. Score the Cut Line: For extremely clean cuts, consider scoring the cut line with a utility knife before making the final cut. This helps to sever the surface fibers and minimize splintering.

Preventing Tearout When Cutting Plywood

Tearout is the bane of every woodworker’s existence when working with plywood. Here are some key strategies for preventing it:

• Sharp Blades: Dull blades are a major cause of tearout. Keep your blades sharp and replace them when they become dull.
• Scoring Cut Lines: As mentioned above, scoring the cut line with a utility knife before cutting can significantly reduce tearout.
• Masking Tape: Applying masking tape along the cut line can provide additional support to the surface fibers. Use high-quality tape that adheres well and doesn’t leave residue.
• Climb Cutting (Use with Extreme Caution): Climb cutting involves feeding the plywood against the direction of blade rotation. This technique can produce very clean cuts but is extremely dangerous and should only be attempted by experienced woodworkers who fully understand the risks of kickback. We do not recommend this technique for beginners.
• Shallow Cuts: Making multiple shallow cuts instead of one deep cut can also help to minimize tearout.
• Backer Board: Use a backer board (a piece of scrap wood) behind the plywood when crosscutting. This provides support and prevents splintering as the blade exits the cut.

Plywood Cutting Guide: Step-by-Step

Here’s a simplified plywood cutting guide:

1. Choose the Right Blade: Select a high-tooth-count blade designed for plywood.
2. Set Up Your Saw: Install a zero-clearance insert and align your fence.
3. Mark Your Cut: Accurately measure and mark the plywood.
4. Prevent Tearout: Use masking tape or score the cut line.
5. Make the Cut: Feed the plywood steadily through the saw, using push sticks for safety.
6. Support the Plywood: Use outfeed supports or a helper.
7. Inspect the Cut: Check for tearout and make any necessary adjustments for future cuts.

Advanced Plywood Cutting Tips

For even better results, consider these advanced techniques:

• Stack Cutting: Stack cutting involves cutting multiple sheets of plywood at once. This can save time and ensure consistent dimensions but requires a powerful saw and extra caution.
• Using a Router Table: A router table can be used to clean up edges and create profiles on plywood. Use a spiral upcut bit for the cleanest results.
• Kerf Width Considerations: Be aware of the kerf (the width of the cut made by the blade). Adjust your measurements accordingly to ensure accurate final dimensions.
• Choosing the Right Plywood: Different types of plywood have different qualities. Baltic birch plywood, for example, is known for its stability and minimal voids, making it a good choice for projects requiring clean cuts.

Common Problems and Solutions

Problem	Possible Cause	Solution
Excessive Tearout	Dull blade, incorrect blade type, fast feed rate	Sharpen or replace blade, use a plywood blade, reduce feed rate, use tape
Burning	Dull blade, slow feed rate, blade height too low	Sharpen or replace blade, increase feed rate, increase blade height
Inaccurate Cuts	Misaligned fence, loose miter gauge, sloppy marking	Align fence, tighten miter gauge, use precise marking tools
Kickback	Binding, pinching, incorrect blade height	Use riving knife, ensure fence is parallel, adjust blade height

Fathoming the Qualities of Different Plywood Grades

Not all plywood is created equal. The grade of plywood you choose can significantly impact the quality of your cuts and the overall appearance of your finished project.

Plywood Grades

• A-Grade: This is the highest quality plywood, with a smooth, sanded surface that is free of knots and imperfections. It is ideal for projects where appearance is critical.
• B-Grade: B-grade plywood may have a few small knots or imperfections but is still generally smooth and paintable.
• C-Grade: C-grade plywood has more knots and imperfections than A or B grade and may require more sanding and filling.
• D-Grade: D-grade plywood is the lowest quality and is typically used for construction purposes where appearance is not important.

Choosing the Right Plywood for Your Project

• For high-end furniture or cabinetry: Use A-grade or Baltic birch plywood.
• For painted projects: B-grade or C-grade plywood may be sufficient.
• For shop cabinets or utility projects: C-grade or D-grade plywood can be used.

FAQ: Cutting Plywood with a Table Saw

What is the best way to cut plywood straight? The best way to cut plywood straight is to use a table saw with a properly aligned fence or a crosscut sled. Measure accurately, support the plywood, and feed it through the saw at a consistent rate.

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, with a high tooth count and an ATB grind, will produce cleaner cuts with less tearout.

Who is at risk of kickback when cutting plywood? Anyone operating a table saw is at risk of kickback. Following safety guidelines, using anti-kickback devices, and maintaining proper technique can significantly reduce the risk.

What are some plywood blade recommendations? Some popular plywood blade recommendations include the Freud LU79R007, the Oshlun SBN-080060, and the CMT 291.064.10.

How do I prevent tearout on the underside of the plywood? Use a zero-clearance insert, apply masking tape along the cut line, and score the cut line with a utility knife.

By following these tips and techniques, you can confidently cut plywood with a table saw and achieve clean, professional results every time. Remember to prioritize safety and practice on scrap material before tackling your final project.