A disc cutter is one of those tools that changes how you work. Instead of sawing out circles by hand and filing them round, you slide in a sheet, drop in a punch, give it a firm blow and out pops a clean, identical disc. It's how most jewellers make blanks for stamped pendants, charms, earrings and domed beads. Here's how to use one properly, and how to choose the right set for what you make.
What a disc cutter actually is
A disc cutter is a hardened steel block with a row of precision holes and a matching punch for each hole. Most are made as two plates with a narrow gap between them. The sheet metal slides into that gap, the punch goes into the top hole, and when you strike the punch it shears straight through the sheet and pushes the shape out of the bottom.
Round cutters are the classic, but the same idea works for shapes too: stars, hearts, crosses, moons, flowers and pendant shapes with a hanging loop already built in.
How to use a disc cutter, step by step
- Use soft, thin sheet. Disc cutters are made for soft metals such as silver, gold, copper and brass. As a rule of thumb, stay at around 1 mm (about 18 gauge) or thinner. If the metal has been worked or feels springy, anneal it first so it cuts cleanly.
- Open the gap and slide the sheet in. Loosen the screws just enough to slide the sheet between the plates, position it under the hole you want, then snug the screws so the sheet can't shift.
- Put the punch in cutting end down. The cutting end is the flat end with the sharp edge. Drop it into the hole so it sits on the metal.
- Work on something solid. Rest the cutter on a steel bench block or anvil, not a soft or springy table. A solid surface puts all the force into the cut.
- Strike firmly with a brass hammer. One or two confident blows cut far better than lots of light taps, which can burr the edge. Use a brass hammer rather than a steel one so you don't mushroom the top of the punch.
- Collect your disc. The shape drops out below. Tap the punch back out, slide the sheet along and go again.
For striking, our 1 lb brass hammer suits most sets, and the 2 lb brass hammer makes larger discs and thicker sheet easier. A steel bench anvil gives you a solid surface to work on.
Tips for cleaner discs
- A drop of oil helps. A light wipe of oil or wax on the punch makes it cut and release more easily.
- Save metal. Start close to the edge of the sheet and work along it, so you get more discs from each piece.
- Keep the punches the right way up. Never strike the cutting end, and keep each punch with its own hole so the edges stay sharp.
- Clean up is quick. A light pass with a fine file or sanding stick removes any slight edge before you stamp or dome.
- Don't force hard metals. Steel, stainless steel and thick sheet will damage the punches.
Which disc cutter set should you buy?
Starting out? A single round cutter covers most first projects. The 14 punch round disc cutter set (3–16 mm) gives you everything from tiny dots for earrings to 16 mm pendant blanks.
Making in volume or selling your work? The round disc cutter set of 3 gives you 26 sizes from 3 to 23 mm across three blocks, so you can make matching discs in almost any size.
Want shapes? Shape cutters save hours of sawing. Popular choices are the star disc cutter, the heart disc cutter and the moon crescent cutter. For pendants ready to hang, the Christmas tree, maple leaf and North Star cutters punch the hanging loop in the same blow.
Making themed collections? The two-block sets, such as moon & star or heart & star, give you matching shapes for earrings, charms and layered pendants.
What to do with your discs next
Discs are just the start. Stamp letters or patterns into them, texture them with a texturing hammer, dome them in a doming block, or layer two shapes and solder them together. If you set stones, a bezel block forms matching round settings to sit on your discs.
You'll find every size and shape in our Mitre Jigs, Disc Cutters & Punches collection. Not sure which set suits your work? Drop us a message and we'll happily help you choose.