When selecting Router Cutters, one of the most important decisions you will make centres on the material they are made from. The two most common options you'll encounter are High-Speed Steel (HSS) and Tungsten Carbide. While they may look similar, their performance, durability, and ideal use cases are worlds apart. Choosing the right material for the job is essential for achieving a clean finish, maximising tool life, and ensuring safe operation.
As a company founded by tradespeople, Key Blades & Fixings understands that the material science behind a cutting edge is what separates a professional tool from a disposable one. This guide will compare HSS and Carbide Router Cutters, explaining their pros and cons so you can make an informed choice for any material you work with, from soft pine to hard oak, MDF, and even plastics.
Understanding the Materials
Before we compare them, let's briefly define what these materials are.
- High-Speed Steel (HSS): HSS is a type of tool steel alloyed with elements like tungsten and molybdenum. It is known for its ability to withstand high temperatures without losing its hardness, which allows it to cut at high speeds. HSS can be honed to an exceptionally sharp edge.
- Tungsten Carbide (often just "Carbide"): Carbide is a composite material made from tungsten carbide particles bonded together in a matrix of cobalt. It is incredibly hard and wear-resistant. Most Router Cutters are not solid carbide but are "carbide-tipped," meaning a steel body has small pieces of carbide brazed onto it to form the cutting edges.
High-Speed Steel (HSS) Router Cutters
HSS was the traditional standard for cutting tools for many years and still has a place in some workshops. These cutters are typically less expensive than their carbide counterparts.
Advantages of HSS:
- Exceptionally Sharp Edge: HSS can be ground to a razor-sharp edge, often sharper than a new carbide bit. This can result in an incredibly clean cut, especially in softwoods.
- Lower Cost: HSS Router Cutters are generally more affordable, making them an attractive option for hobbyists or for tasks where the bit might be damaged.
- Easier to Sharpen: While professional sharpening is still recommended, HSS is easier to hone and resharpen than carbide.
Disadvantages of HSS:
- Poor Heat Resistance: Despite its name, HSS loses its hardness (temper) at high temperatures. The friction generated during routing, especially in hard materials, quickly heats the bit and dulls the edge.
- Lack of Durability: The edge on an HSS bit wears down very quickly compared to carbide. It is not suitable for abrasive materials like MDF or particleboard, which will destroy the edge almost instantly.
- Limited Lifespan: Because it dulls so fast, an HSS bit needs frequent sharpening and has a much shorter overall service life.
When Should You Use HSS Router Cutters?
The use case for HSS Router Cutters today is very narrow. They are best reserved for specific, light-duty applications where the sharpest possible edge is required for a superior finish.
- Softwoods Only: HSS performs best in soft, non-resinous woods like pine or poplar, where heat build-up is minimal.
- Hand-Carving or Specialty Work: For delicate, one-off tasks where an extremely fine finish is the top priority, a freshly sharpened HSS bit can excel.
For general-purpose routing, HSS is largely considered an obsolete technology. The speed and power of modern routers generate too much heat for HSS to remain effective for long.
Carbide-Tipped Router Cutters
Carbide-tipped Router Cutters are the undisputed industry standard for both professionals and serious DIYers. The combination of a tough steel body and incredibly hard carbide cutting edges offers the best of both worlds.
Advantages of Carbide:
- Exceptional Durability and Wear Resistance: Carbide is significantly harder than HSS and can hold its cutting edge up to 25 times longer. It is built for long-term, heavy-duty use.
- Superior Heat Resistance: Carbide excels at maintaining its hardness even at the high temperatures generated during routing. This prevents the edge from dulling quickly and drastically reduces burning on the workpiece.
- Material Versatility: This is the key advantage. Carbide Router Cutters can handle virtually any material you throw at them, from the softest woods to the hardest, as well as composites, laminates, and plastics.
- Long-Term Value: While the initial cost is higher, the extended lifespan and superior performance of carbide bits offer far better value for money in the long run.
Disadvantages of Carbide:
- More Brittle: Because it is so hard, carbide is also more brittle than H.S.S. A sharp knock or dropping the cutter on a concrete floor can chip or crack the cutting edge.
- Higher Initial Cost: Carbide-tipped Router Cutters are more expensive to manufacture, which is reflected in their price.
- Difficult to Sharpen: Sharpening carbide requires specialised diamond-honing equipment and is a job for a professional service.
Material Showdown: Carbide vs. HSS for Your Project
Let's break down which cutter material works best for common workshop materials.
Hardwoods (Oak, Maple, Walnut)
Winner: Carbide
Hardwoods create significant friction and heat. An HSS bit would dull almost immediately, leading to friction burns and a poor finish. The heat and wear resistance of carbide-tipped cutters is essential for cleanly shearing the dense fibres of hardwood. The result is a crisp, clean cut without burn marks.
Softwoods (Pine, Cedar, Fir)
Winner: Carbide
While a very sharp HSS bit can provide a beautiful finish on softwood, it won't stay sharp for long. Resinous pines can also cause significant pitch build-up, which leads to heat. A quality carbide cutter will stay sharp through countless projects, offering more consistent results and a much longer life, making it the practical choice.
MDF, Particleboard, and Plywood
Winner: Carbide (by a landslide)
These man-made materials are extremely abrasive. They are made of wood fibres held together with glue and resins, which act like sandpaper on a cutting edge. An HSS router cutter would be rendered useless after just a few feet of cutting. Plywood also contains layers of glue that are tough on cutters. Carbide is the only material that can withstand this level of abrasion and provide a clean cut without immediate failure.
Plastics and Solid Surfaces (Acrylic, Corian)
Winner: Carbide
Plastics require a very sharp and heat-resistant edge. The wrong bit can melt the plastic rather than cut it, leaving a messy, gummed-up edge. Specifically designed carbide cutters, sometimes with unique geometries to aid chip ejection, are needed to get a clean, polished edge. HSS would overheat and fail quickly.
The Verdict: Why Carbide is the Professional's Choice
For virtually all modern routing applications, carbide-tipped Router Cutters are the superior choice. Their durability, heat resistance, and versatility make them the most reliable and cost-effective option for any material you might encounter. While an HSS bit might have a niche use for a delicate finishing pass on soft pine, it simply cannot compete with the all-around performance of carbide.
Investing in a set of high-quality carbide-tipped Router Cutters is an investment in the quality of your work. They will produce cleaner results, last significantly longer, and give you the confidence to tackle any project, knowing your tools are up to the task.