DeWalt 20V MAX XR Mid-Size Bandsaw

Why this mid-size bandsaw earned a spot in my kit

I’ve been looking for a metal-cutting option that’s faster and cleaner than a grinder but more portable than a corded deep-cut saw. This mid-size 20V bandsaw hits a sweet spot. It’s compact enough to carry up ladders, balanced well for one- or two-handed use, and strong enough to handle the materials I cut most often: 1-5/8 in strut, EMT, copper, threaded rod, small angle, and the occasional piece of rebar. After several weeks of jobsite and shop use, it’s clear DeWalt built this saw with the right priorities—power, control, and real-world ergonomics—while leaving a couple of practical considerations you’ll want to plan around.

Build, balance, and controls

Bare, the saw weighs 8.4 lb. With a typical 20V pack installed, it still feels notably lighter than a deep-cut, and that matters when you’re cutting overhead or with arms outstretched. The handle geometry encourages a natural, two-handed grip: rear trigger hand to control speed and a forward hand on the frame to steer the cut. The integrated blade guard keeps more of the band enclosed than older designs, which boosts confidence when you’re working in tight racks or near finished surfaces.

Two control features make this saw easy to live with:

• A variable-speed trigger paired with a top-mounted speed dial. I run the dial as a “ceiling” and then meter with the trigger. That combination prevents accidental over-speed on thin materials but still gives instant control for starts and break-throughs.
• A bright LED that throws useful light right at the cut line. It’s not a floodlight, but it helps when you’re tucked into a mechanical room or hanging from a lift.

There’s a lanyard-capable point for tethering, which I appreciate for overhead work, and the tool is “Tool Connect” chip-ready if you’re managing a fleet and want tracking or inventory features. No battery or charger is included; this is a bare tool.

Capacity and what it realistically cuts

The published capacity is 3-3/8 in. In practice, that means:

• Round: Anything up to 3-3/8 in diameter. That covers conduit and pipe up to 2-1/2 in nominal steel pipe (2.875 in OD). Three-inch steel pipe (3.5 in OD) is a no-go in a single pass.
• Channel and shapes: Strut, angle, and flat bar in the typical ranges used by electrical and mechanical trades fit comfortably.
• Threaded rod and rebar: No issues with 3/8 in to 5/8 in material, provided you match blade TPI and speed.

If you routinely cut 4–5 in stock, you’ll still want a deep-cut. But for most service and install tasks, this mid-size format gets into places a deep-cut simply won’t, and it’s less fatiguing to use.

Power and speed

The brushless motor is rated at 535 MWO with a top speed of 570 SFPM, and the saw doesn’t feel starved. It keeps its pace through 12-gauge strut and common steel shapes without bogging, and the variable speed range drops low enough for stainless and harder alloys. The dial has distinct steps, and I found a middle setting ideal for general mild steel, bumping slower for stainless to avoid work-hardening, and faster for aluminum or plastic.

Noise and vibration are both low compared to abrasive cutting. You get a smooth feed and clean, burr-light cut faces that typically only need a quick touch-up.

On runtime, the spec claims up to 120 cuts per charge through 12-gauge strut (battery dependent). Real-world results depend on battery size and what you’re cutting, but the efficiency of a bandsaw is noticeable. On service calls, I rarely reach for a second battery unless I’m making lots of repetitive cuts.

Blade system and changeover

This saw uses a 35-3/8 in by 1/2 in blade—common across many compact and mid-size portables. It ships with an 18 TPI bimetal blade that’s well-suited to mild steel in the thicknesses most of us see. Blade changes are straightforward: release tension, slip the band off/on, tension, then fine-tune tracking with the included hex wrench. The tracking adjustment is responsive, and once set for a given blade brand/width, I didn’t need to fuss with it frequently.

A practical note: success with portable bandsaws lives and dies on blade quality. Don’t cheap out. Keep a small selection on hand:
- 14–18 TPI: general mild steel, EMT, strut
- 18–24 TPI: thin-wall tubing and sheet to reduce tooth catching
- 8–10 TPI: aluminum and thicker solids
- Carbide or heavy-duty bimetal: for abrasive stuff like rebar

Finding good 35-3/8 in blades locally can be hit-or-miss depending on your area. If your usual supplier stocks limited options, order quality bimetal blades from industrial suppliers and keep a few spares in your kit.

Cut quality and technique

This is where the saw shines. Starts are predictable—you can bump the trigger to score without grabbing—and the band tracks straight with minimal tendency to wander when you let the tool do the work. My best results came from:

• Setting the speed dial for the material, then modulating with the trigger.
• Letting the saw’s weight feed the cut; don’t muscle it.
• Supporting the work to eliminate vibration, especially on thin-wall or threaded rod.
• For round stock, keeping the frame square and letting the full width of the band engage early.

The LED helps keep your mark in view, and the enclosed guard limits chip spray. Chips mostly fall clear of the cut path, which keeps the band from riding up on its own debris.

Ergonomics and safety

The overall balance is excellent. With a compact battery, the center of mass sits near the frame opening, so it doesn’t torque your wrist. The grip texture is secure without being too aggressive, and the trigger pull is light enough for extended use. The guard design protects hands and surroundings well, and visibility into the cut window is good for a mid-size.

A tether point makes the saw workable on lifts and ladders, and that’s not a small thing. I’d still like to see a rafter hook on tools like this, but the tether ring is a practical alternative when you can’t safely set the saw down.

Maintenance and durability

Brushless motors are practically maintenance-free, and the drivetrain feels tight. The wheels and guides stayed clean and true while cutting steel, and the included wrench for blade tracking and fence tweaks lives onboard, which means you’re less likely to misplace it. As with any bandsaw, check tension when you install a new blade and after the first few cuts—it’ll stretch slightly as it warms. The 3-year limited warranty adds some peace of mind for regular jobsite use.

Limitations to consider

• Capacity ceiling: 3-3/8 in is generous for a compact form factor, but it won’t replace a deep-cut if you’re frequently tackling 4–5 in stock or 3 in nominal steel pipe.
• Blades: The tool’s performance is tied to blade quality, and depending on where you shop, premium 35-3/8 in blades aren’t always sitting on the shelf. Plan ahead and stock up.
• Bare tool: If you’re not already on DeWalt 20V MAX batteries, you’ll need to budget for packs and a charger.

None of these are deal-breakers for the intended use, but they’re worth weighing for your workflow.

Who benefits most

• Electricians and MRO techs cutting strut, EMT, and threaded rod on site.
• Plumbers/HVAC techs handling copper, PVC, and smaller steel pipe where a deep-cut is overkill.
• Fabricators who want a portable, low-spark option for trimming small stock without hauling material to a stationary saw.

If your work is primarily shop-based with larger sections, a benchtop or deep-cut solution will be more efficient. If you’re mobile and working in tight mechanical spaces, this mid-size is the right tool.

Recommendation

I recommend this mid-size DeWalt bandsaw for anyone who needs a portable, low-spark metal-cutting solution with better capacity and speed than the ultra-compact class, but without the weight and bulk of a deep-cut. It’s powerful for its size, the trigger-and-dial speed control is genuinely useful, and the ergonomics make it comfortable for overhead and awkward cuts. Plan to invest in quality 35-3/8 in blades and keep a few TPIs on hand—that’s the difference between “pretty good” and “excellent” performance. If your work regularly exceeds 3-3/8 in capacity, step up to a deep-cut. Otherwise, this saw hits a very practical balance and has earned a spot in my everyday kit.