Cutting Plywood with a Jigsaw

Master the Art of Cutting Plywood with a Jigsaw: Step-by-Step Guide

Are you looking to master the art of cutting plywood with a jigsaw? Look no further! In this step-by-step guide, we will walk you through the process of using a jigsaw to cut plywood like a pro. Whether you’re a beginner or have some experience with woodworking, this comprehensive guide will provide you with the knowledge and techniques you need to achieve clean, precise cuts every time.

Using a jigsaw for cutting plywood offers flexibility and control, making it one of the most versatile tools in a woodworker’s arsenal. However, it can be intimidating for beginners. That’s why our guide is designed to break down the process into simple, easy-to-follow steps. From selecting the right jigsaw blade to positioning and securing the plywood, we’ve got you covered.

By mastering the art of cutting plywood with a jigsaw, you’ll be able to tackle a wide range of projects, from building furniture to making intricate cuts for crafts. So grab your jigsaw, and let’s get started on your journey to becoming a plywood-cutting pro!

Tools and Materials Needed for Cutting Plywood:

Before we dive into the process of cutting plywood with a jigsaw, let’s start by gathering the necessary tools and materials. Here are the essentials you’ll need:

1. Jigsaw: Choose a jigsaw that is suitable for cutting plywood. Look for a model with variable speed control and orbital action for added versatility.

2. Jigsaw blades: Selecting the right jigsaw blade is crucial for achieving clean and accurate cuts. Opt for a blade specifically designed for cutting plywood. The number of teeth per inch (TPI) will depend on the thickness of the plywood.

3. Plywood: Use high-quality plywood for best results. The thickness of the plywood will vary depending on your project.

4. Clamps: Clamps are essential for securing the plywood in place and preventing it from moving during the cutting process.

5. Safety equipment: Always prioritize safety when working with power tools. Wear safety goggles, a dust mask, and ear protection to protect yourself from dust and noise.

Now that you have all the necessary tools and materials let’s move on to selecting the right jigsaw blade for cutting plywood.

Choosing the Right Jigsaw Blade for Plywood:

The jigsaw blade you choose will significantly impact the quality of your cuts. When it comes to cutting plywood, there are a few factors to consider when selecting the right jigsaw blade:

1. TPI (teeth per inch): The TPI of a jigsaw blade determines how quickly it cuts through the material. For plywood, a blade with a higher TPI (around 10-12) is recommended for cleaner and smoother cuts.

2. Blade material: Jigsaw blades are available in various materials, including high-carbon steel, bi-metal, and carbide-tipped. For cutting plywood, a bi-metal blade is a popular choice due to its durability and versatility.

3. Blade thickness: The thickness of the blade should match the thickness of the plywood. Using a blade that is too thick can lead to excess friction and burning, while a blade that is too thin may result in a less stable cut.

Once you have selected the appropriate jigsaw blade for cutting plywood, it’s time to set up your workspace.

Setting up Your Workspace for Cutting Plywood:

Creating a suitable workspace is essential for achieving accurate and safe cuts. Follow these steps to set up your workspace for cutting plywood with a jigsaw:

1. Clear the area: Ensure that your workspace is clean and free from any obstacles that could interfere with the cutting process. Remove any loose objects and clutter.

2. Secure the plywood: Use clamps or a workbench to secure the plywood in place. This will prevent it from moving during the cutting process, ensuring clean and precise cuts.

3. Mark the cut line: Use a pencil and a straightedge to mark the desired cut line on the plywood. Double-check your measurements to ensure accuracy.

Now that your workspace is ready, it’s time to dive into the step-by-step guide for cutting plywood with a jigsaw.

Step-by-step Guide to Cutting Plywood with a Jigsaw:

1. Insert the jigsaw blade: Start by inserting the selected jigsaw blade into your jigsaw. Follow the manufacturer’s instructions for proper blade insertion.

2. Position the jigsaw: Position the jigsaw on the edge of the plywood, aligning the blade with the marked cut line. Ensure that the jigsaw is stable and secure.

3. Start the jigsaw: Turn on the jigsaw and allow it to reach full speed before making contact with the plywood.

4. Begin cutting: Gently guide the jigsaw along the marked cut line, applying steady and even pressure. Let the jigsaw do the work and avoid forcing it through the plywood.

5. Follow the cut line: Keep your eyes on the marked cut line and follow it closely with the jigsaw. Take your time and make smooth, controlled movements.

6. Pivot when necessary: If you encounter curves or corners during the cut, pivot the jigsaw smoothly to follow the desired shape. Take care to maintain a steady hand and avoid rushing.

7. Complete the cut: Continue cutting along the marked line until you reach the end. Slow down as you approach the end to ensure a clean and accurate cut.

8. Remove the plywood: Once the cut is complete, turn off the jigsaw and carefully remove it from the plywood. Release any clamps and set aside the cut piece.

Tips for Achieving Clean and Accurate Cuts:

Cutting plywood with a jigsaw requires precision and technique. Here are some tips to help you achieve clean and accurate cuts:

1. Take it slow: Avoid rushing through the cut. Take your time and maintain a steady hand for smooth and precise cuts.

2. Support the plywood: Use additional support, such as sawhorses or a workbench, to stabilize the plywood and reduce vibrations during the cut.

3. Use a guide: For longer cuts, consider using a straightedge or a guide rail to ensure a straight and accurate cut.

4. Cut slightly outside the line: To account for the width of the jigsaw blade, aim to cut slightly outside the marked cut line. This will help you achieve a clean and accurate final cut.

5. Practice on scrap plywood: If you’re new to cutting plywood with a jigsaw, it’s a good idea to practice on scrap pieces before working on your actual project. This will allow you to refine your technique and gain confidence.

Common Mistakes to Avoid When Cutting Plywood with a Jigsaw:

Common mistakes to avoid when cutting plywood with a jigsaw.

While cutting plywood with a jigsaw can be relatively straightforward, there are some common mistakes to avoid:

1. Using the wrong blade: Using a blade that is not suitable for plywood can result in rough cuts and splintering. Always choose the appropriate jigsaw blade for the task at hand.

2. Applying too much pressure: Let the jigsaw do the work. Applying excessive pressure can lead to overheating, burning, and less precise cuts.

3. Not securing the plywood: Failing to secure the plywood can result in movement during the cut, leading to inaccurate and uneven cuts. Always use clamps or a workbench to secure the plywood firmly.

4. Ignoring safety precautions: Always prioritize safety when using a jigsaw. Wear the necessary safety equipment, such as goggles, a dust mask, and ear protection, to protect yourself from potential hazards.

Finishing Techniques for Plywood Edges:

Once you have made your cuts, you may want to consider finishing the edges of the plywood for a polished look. Here are some finishing techniques you can try:

1. Sanding: Use sandpaper or a sanding block to smooth out the edges of the plywood. Start with a coarse-grit sandpaper and gradually move to finer grits for a smooth finish.sandpaper

2. Router: If you have access to a router, consider using it to round over or chamfer the edges of the plywood for a more decorative look.


3. Edge banding: For a professional finish, you can apply edge banding to the exposed edges of the plywood. Edge banding is available in various materials, such as wood veneer or PVC, and can be easily applied using an iron or a hot air gun.

Edge banding

Safety Precautions When Using a Jigsaw to Cut Plywood:

Safety should always be a top priority when working with power tools like a jigsaw. Here are some safety precautions to keep in mind:

1. Wear safety goggles: Protect your eyes from flying debris by wearing safety goggles.

2. Use a dust mask: Plywood can produce a significant amount of dust when cut. Wear a dust mask to avoid inhaling harmful particles.

3. Wear ear protection: Jigsaws can generate loud noise levels. Protect your hearing by wearing ear protection.

4. Keep fingers clear: Always keep your fingers clear of the jigsaw blade and ensure that they are at a safe distance from the cutting area.

5. Disconnect power when changing blades: Before changing the jigsaw blade, disconnect the power source to avoid accidental activation.


Mastering the art of cutting plywood with a jigsaw is a valuable skill for any woodworker. With the right tools, techniques, and safety precautions, you can achieve clean and precise cuts every time. Remember to choose the appropriate jigsaw blade, secure your workspace, and follow the step-by-step guide to ensure optimal results. With practice and patience, you’ll be able to tackle a wide range of projects and unleash your creativity with plywood cuts. So grab your jigsaw, put on your safety gear, and let your woodworking journey begin!

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