DeWalt 20V MAX XR Mid-Size Bandsaw (5.0Ah Battery Kit)

Why I reached for a mid‑size bandsaw

There’s a sweet spot between compact, one‑hand bandsaws that top out on capacity and the deep‑cut beasts that feel overkill on a lift. That’s where this mid‑size DeWalt bandsaw lives. After a few weeks of cutting strut, EMT, threaded rod, and angle in real jobsite conditions, it’s become the saw I grab most often when I’m not sure what the day will bring. It’s light enough to live on my harness, strong enough to keep its speed under load, and its 3-3/8 in cut capacity covers the majority of electrical and mechanical stock I see.

Power and speed

DeWalt rates the brushless motor at 535 MWO (max watts out) with a top blade speed of 570 SFPM. Specs aside, what matters is how it feels mid‑cut. The saw holds pace confidently through 12 gauge strut and 2-1/2 in EMT without bogging. On repetitive strut, my cut times averaged right around five seconds, which tracks with DeWalt’s claim. I rarely needed full speed; the variable speed dial sets a top speed, and the trigger allows fine control. That combo makes it easy to keep teeth engaged cleanly on thin wall conduit or slow down for stainless and hardened fasteners.

If you’re coming from a compact bandsaw, the extra power is immediately noticeable, especially on thicker wall tube and angle. It doesn’t surge at the start or stall when you edge into a cut. Compared to the big deep‑cut saws, this one isn’t quite as brute‑force on heavy bar, but for field installs it’s a smarter compromise.

Cutting performance

Cut quality is the reason to prefer a bandsaw over a recip or cut‑off wheel, and this saw delivers. With the included 18 TPI 35-3/8 in blades, cuts on mild steel were consistently square and burr‑light. The integrated guard keeps chips in check and routes debris away from the cut line better than I expected. You’ll still want eye protection—metal chips go everywhere—but cleanup was noticeably reduced compared to open‑frame compacts I’ve used.

Capacity at 3-3/8 in is more useful than it sounds on paper. It swallows 2-1/2 in EMT (OD ≈ 2.875 in), strut, threaded rod bundles, and most angle and channel used in hangers. It will not make it around 3 in EMT or a 4x4, and it’s not intended for big structural cuts—that’s still deep‑cut territory. Within its lane, it’s confident and accurate.

Blade tracking stayed true throughout testing. The saw includes a hex wrench for blade tracking and fence adjustment, but I only needed a minor tweak after switching to a different blade brand. The fence keeps the work supported and helps new users keep cuts square. I appreciated that I could tip the saw slightly to sneak the start of a cut on round stock without skating.

Ergonomics and control

At 8.4 lb bare tool, the balance is excellent, especially with a 5.0Ah pack. The center of gravity sits where your forward hand wants to be, so wrist strain is minimal on overhead work. The handle and auxiliary grip offer a natural two‑hand stance, but one‑handed trimming on hanging rod felt controlled. The variable speed dial falls under the thumb, and the trigger is progressive without being jumpy.

The LED work light is bright and, more importantly, well‑placed. It illuminates the cut path without throwing a hard shadow from the guard. In a dim mechanical room, that made it easier to follow a mark on conduit without over‑relying on feel.

Noise is modest compared to a grinder or recip saw, and the lack of sparks is a big win when you’re near finished surfaces or fire protection. Chips are hot, but they mostly collect within the guard and fall out predictably.

Battery life and runtime

With the included 5.0Ah battery, I made a morning’s worth of cuts on strut and rod without swapping packs. On repetitive cuts through 12 gauge strut, I hit “about a hundred‑plus” cuts per charge, which aligns with the published “up to 120” figure. As always, material, blade selection, and how often you run at full speed will move the needle. The brushless motor clearly helps here—there’s none of the sag I see with older brushed bandsaws as the pack drops.

Charging on the included DCB1104 is straightforward. I can’t speak to exact charge times, but it turned packs around fast enough to keep up.

Features that matter onsite

• Variable speed trigger and dial: I set the dial around the middle for most work and let the trigger do the fine work. For stainless or thicker wall, rolling the dial down prevented tooth chatter and prolonged blade life.
• Integrated blade guard: Gives a little more confidence when working close to ceiling tile or finished walls and keeps chips corralled. It does tighten the space around the blade slightly compared to open designs, but I never felt constrained on typical materials.
• Built‑in LED: Simple and effective. It’s one of those features you forget about until you pick up a tool without it.
• Tool Connect chip pocket: If you manage a fleet, the DCE042 module drops in and lets you track assets without a clunky add‑on. I ran it without the chip, but the pocket is there and protected.
• Lanyard attachment point: For overhead or lift work, tethering is non‑negotiable. The attachment point is ready, and the lanyard capability is available as of January 2025. Nice touch for safety‑focused jobsites.

Blade options and maintenance

It takes standard 35-3/8 in (900 mm) bandsaw blades, so replacements are easy to source. The included pair of 18 TPI blades is a good general‑purpose choice. For thin‑wall conduit, 24 TPI smooths the cut; for thicker stock, 14 TPI keeps the feed rate up. Blade changes were straightforward, and the tracking held after swaps with only minor tweaks. Keep a brush handy to clear chips from the wheels and the guard; doing so every few battery swaps kept everything running smoothly.

Build quality and durability

Fit and finish are solid. The wheel doors close securely, the guard doesn’t rattle, and the rubber overmold is grippy without feeling gummy. After a couple of weeks of normal jobsite abuse—dust, occasional bumps into channel, riding in a crowded gang box—the saw shows scuffs but no mechanical issues. The brushless drivetrain should help longevity, and the 3‑year limited warranty offers some peace of mind.

Where it fits—and where it doesn’t

This saw is a great match for:
- Electricians cutting EMT, strut, and threaded rod up to 2-1/2 in.
- Plumbers and HVAC techs working with thin‑ to mid‑wall tube, angle, and channel.
- Fabrication tasks on lifts where a deep‑cut saw is too heavy and a compact saw runs out of capacity.

It’s not the right tool if you routinely cut 3 in EMT, large angle, or structural stock—get a deep‑cut. And if your work rarely exceeds threaded rod and 1‑1/4 in conduit, a compact bandsaw will be lighter and cheaper.

Limitations to note

• Capacity ceiling at 3-3/8 in: Know your material list. If you bump into 3.5 in OD often, you’ll be frustrated.
• Top speed of 570 SFPM: Plenty for mild steel, but stainless requires patience. The variable speed helps, just don’t expect miracles.
• Guard design: I like the debris control, but it slightly narrows access around odd‑shaped workpieces compared to fully open frames.

None of these were deal‑breakers for me, but they’re worth considering.

What’s in the kit

The kit is thoughtfully bundled for someone starting fresh:
- Mid‑size bandsaw
- Two 18 TPI 35-3/8 in blades
- Blade tracking and fence adjusting hex wrench
- 5.0Ah 20V MAX XR battery (DCB205)
- Charger (DCB1104)
- Soft kit bag

You can go to work immediately without hunting for blades or a spare battery.

Recommendation

I recommend this mid‑size DeWalt bandsaw to tradespeople who need more capacity and power than a compact saw without stepping up to a deep‑cut. It strikes an excellent balance: strong, steady cutting performance; practical runtime on a 5.0Ah pack; and jobsite‑friendly features like the LED, integrated guard, and tether point. The 3-3/8 in capacity covers the bulk of everyday metal cuts in electrical and mechanical work, and the standard 35-3/8 in blade size keeps consumables simple. Its limitations are clear and reasonable: if you regularly cut beyond its capacity, choose a deep‑cut; if you rarely approach its limits, a compact may save weight. For the broad middle of jobsite cutting tasks, this saw is the right tool more often than not.