How To Cut Plywood With Table Saw: Achieve Perfect Results

Cutting plywood with a table saw can be tricky, and you can achieve perfect results by using the correct techniques, blade, and safety measures. This article will explore plywood cutting techniques, choosing the right table saw blade for plywood, achieving splinter-free plywood cuts, considering the best table saw for plywood, providing plywood ripping tips and crosscutting plywood techniques, tackling large plywood sheets, preventing tearout when cutting plywood, utilizing helpful plywood cutting jigs, and ensuring safe plywood cutting practices.

Image Source: i.ytimg.com

Choosing the Right Table Saw Blade for Plywood

The key to splinter-free cuts is selecting the right blade. The ideal table saw blade for plywood will minimize tearout and produce clean edges.

Tooth Count and Grind: Important Factors

• High Tooth Count: Blades with a higher tooth count (60-80 teeth for a 10-inch blade) are best. More teeth mean smaller bites, reducing chipping.
• Alternate Top Bevel (ATB) Grind: ATB blades have teeth that alternate bevels, slicing the wood fibers rather than tearing them.
• Triple Chip Grind (TCG): While excellent for hardwoods and abrasive materials, TCG blades can sometimes be used for plywood, especially if tearout is a major concern. However, an ATB is usually preferred.

Blade Quality Matters

Investing in a high-quality blade is crucial. Cheaper blades often lack precision grinding and use lower-grade materials, leading to poor cuts and premature dulling. Look for blades made from high-speed steel (HSS) or carbide-tipped blades. Carbide-tipped blades are more durable and stay sharp longer, making them ideal for frequent plywood cutting.

Blade Type Comparison

Blade Type	Tooth Count	Grind	Pros	Cons	Best For
ATB	60-80	ATB	Clean cuts, minimal tearout, versatile	May dull faster than TCG on very hard materials	General plywood cutting, fine furniture
TCG	40-60	TCG	Durable, good for abrasive materials	Can sometimes cause more tearout on plywood than ATB	Melamine, laminate, plywood (use with caution)
Combination	40-50	ATB/R	Decent for both ripping and crosscutting, a good all-around choice	Not as specialized as dedicated ripping or crosscutting blades	General-purpose use when blade changes aren’t convenient
Plywood Specific	80+	Special ATB	Designed specifically for plywood, offering the cleanest possible cuts	May be more expensive, not ideal for other materials	High-quality plywood projects, cabinetry

Techniques for Splinter-Free Plywood Cuts

Beyond the blade, your cutting technique significantly impacts the quality of the cut. Here are some strategies to minimize tearout and achieve clean, professional results.

Scoring Cut: A Crucial Step

Before making a full cut, perform a scoring cut. This shallow pass (about 1/8 inch deep) pre-cuts the surface fibers, preventing them from tearing out during the main cut.

• How to do it: Set the blade height to approximately 1/8 inch. Run the plywood through the saw. Then, raise the blade to the desired cutting height and complete the cut.

Feed Rate: Finding the Right Speed

The speed at which you feed the plywood into the blade also matters.

• Too fast: Can cause the blade to bog down and tear the wood.
• Too slow: Can cause burning and uneven cuts.

A moderate, steady feed rate is ideal. Let the blade do the work; don’t force it.

Zero-Clearance Insert: Minimizing Gaps

A zero-clearance insert is a throat plate with a very tight opening around the blade. This close fit supports the wood fibers right next to the cut, preventing them from lifting and tearing.

• Why it works: Standard throat plates have a wider opening, allowing the wood to vibrate and splinter. A zero-clearance insert eliminates this space.
• Making your own: You can purchase or make your own zero-clearance insert. To make one, use a blank insert and raise the blade through it. This creates a perfect fit for your blade.

Painter’s Tape: An Extra Layer of Protection

Applying painter’s tape along the cut line can provide an additional layer of support and prevent tearout, especially on delicate veneers.

• How to use it: Apply two layers of tape on both sides of the cut line. The blade will cut through the tape, further stabilizing the wood fibers.

Ripping Plywood on a Table Saw: Long Grain Cuts

Ripping is cutting plywood with the grain (along its length). This often involves handling large sheets, so safety and control are paramount.

Supporting Large Sheets

Cutting large sheets of plywood alone can be dangerous. Use outfeed supports, roller stands, or enlist a helper to support the weight of the material. This prevents the plywood from sagging and binding on the blade.

Using a Ripping Fence

The rip fence guides the plywood, ensuring a straight, accurate cut.

• Fence Alignment: Ensure the fence is parallel to the blade. Misalignment can cause binding and kickback.
• Featherboards: Use featherboards to keep the plywood pressed against the fence, maintaining consistent pressure and preventing movement.

Plywood Ripping Tips

• Plan your cuts: Before you start, carefully plan your cuts to minimize waste and ensure you get the pieces you need.
• Consider the grain direction: The orientation of the grain can affect the strength and appearance of the finished product.
• Make relief cuts: For long, thin strips, make relief cuts to prevent the wood from binding and warping.

Crosscutting Plywood on a Table Saw: Short Grain Cuts

Crosscutting is cutting plywood against the grain (across its width). Accuracy is especially important in crosscuts.

Using a Miter Gauge

A miter gauge slides in a slot on the table saw and guides the plywood across the blade at a specific angle.

• Miter Gauge Accuracy: Ensure your miter gauge is accurate and doesn’t have excessive play.
• Extension Fence: Attach an extension fence to the miter gauge to provide more support for the plywood.

Crosscutting Sled: The Ultimate Tool for Accuracy

A crosscutting sled is a jig that rides in the miter slots and provides a stable platform for crosscutting plywood.

• Benefits: Sleds offer superior accuracy, support, and safety compared to using a miter gauge alone.
• Building a Sled: Numerous plans are available online for building your own crosscutting sled.

Plywood Crosscutting Tips

• Slow and Steady: Feed the plywood slowly and steadily into the blade.
• Support the Plywood: Ensure the plywood is fully supported to prevent it from tipping or shifting.
• Double-Check Measurements: Before making the cut, double-check your measurements to ensure accuracy.

Cutting Large Plywood Sheets Safely

Large plywood sheets pose unique challenges. Here’s how to manage them safely:

Adequate Support is Key

As mentioned earlier, support is crucial. Use outfeed tables, roller stands, or a helper to prevent the sheet from sagging.

Breaking Down the Sheet

Consider breaking down the large sheet into smaller, more manageable pieces before making final cuts. This can be done with a circular saw and a straight edge.

Gradual Cuts

Avoid trying to cut through thick plywood in a single pass. Make multiple shallow cuts, gradually increasing the blade height until you reach the desired depth. This reduces stress on the blade and the saw.

Safety Gear

Always wear safety glasses, hearing protection, and a dust mask when cutting plywood. Plywood dust can be irritating and harmful if inhaled.

Avoiding Tearout When Cutting Plywood

Here’s a summary of tips to prevent tearout:

• Use a high-tooth-count ATB blade.
• Perform a scoring cut.
• Use a zero-clearance insert.
• Apply painter’s tape along the cut line.
• Maintain a moderate feed rate.

Plywood Cutting Jigs: Enhancing Accuracy and Safety

Jigs can significantly improve the accuracy and safety of plywood cutting.

Tapering Jig

Used for cutting tapered pieces of plywood.

Circle Cutting Jig

Allows you to cut perfect circles in plywood.

Spline Jig

For cutting slots for splines, reinforcing joints.

Homemade Jigs

Consider making custom jigs for specific projects.

Safe Plywood Cutting Practices

Safety should always be your top priority.

Wear Safety Gear

• Safety Glasses: Protect your eyes from flying debris.
• Hearing Protection: Table saws are loud; protect your hearing.
• Dust Mask: Plywood dust can be harmful; wear a dust mask or respirator.

Know Your Saw

• Read the Manual: Familiarize yourself with your saw’s features and safety guidelines.
• Inspect the Saw: Before each use, inspect the saw for any damage or loose parts.

Use Push Sticks and Push Blocks

These tools keep your hands away from the blade. Never reach over or near the blade with your hands.

Avoid Kickback

Kickback occurs when the wood is pinched between the blade and the fence, causing it to be thrown back towards the operator.

• Preventing Kickback:
  • Use a splitter or riving knife.
  • Ensure the fence is parallel to the blade.
  • Use featherboards.
  • Don’t force the wood.

Stay Focused

Avoid distractions when operating a table saw.

Choosing the Best Table Saw for Plywood

While any table saw can cut plywood, some are better suited for the task than others. Factors to consider include:

• Power: A more powerful saw will handle thicker plywood with ease.
• Table Size: A larger table provides more support for large sheets.
• Fence Quality: A precise and sturdy fence is essential for accurate cuts.
• Dust Collection: Plywood cutting produces a lot of dust, so good dust collection is important.

Table Saw Types

Table Saw Type	Pros	Cons	Best For
Contractor Saw	Affordable, portable, decent power	Less precise than cabinet saws, can vibrate more	Hobbyists, small shops, occasional plywood cutting
Cabinet Saw	Powerful, precise, stable, excellent dust collection	More expensive, less portable	Professionals, frequent plywood cutting, demanding accuracy
Hybrid Saw	A balance of contractor and cabinet saw features	Can be more expensive than contractor saws, less powerful than cabinet saws	Serious hobbyists, small shops, regular plywood cutting
Jobsite Saw	Very portable, compact, lightweight	Less powerful, less precise, smaller table	On-site work, limited space, occasional plywood cutting

Frequently Asked Questions (FAQ)

What is the best blade for cutting plywood?

The best blade is a high-tooth-count (60-80 teeth) ATB (Alternate Top Bevel) blade designed for plywood.

Can I use a regular blade to cut plywood?

Yes, but you’ll likely experience more tearout. A blade designed for plywood is highly recommended for cleaner cuts.

Who is the best person to ask for help with my table saw?

Consult experienced woodworkers, local woodworking clubs, or professional tool repair technicians.

How can I prevent tearout on the bottom of the plywood?

Use a zero-clearance insert and apply painter’s tape to the underside of the plywood.

What is a scoring cut?

A shallow first pass to pre-cut the surface fibers before making a full cut. This helps prevent tearout.

Is it safe to cut large plywood sheets by myself?

It’s generally not recommended. Use outfeed supports, roller stands, or a helper to support the weight of the material.