Start With Sharp Tools
The foundation of clean cutting starts with sharp tools. Whether it’s a circular saw, router, or chisel, a sharp blade slices fibres cleanly rather than tearing them. Dull blades apply excessive pressure, increasing the risk of tearout significantly.
Slow Down the Cut
Rushing through a cut, especially on power tools, increases the chance of fibres being ripped rather than cut. Let saws and routers get up to speed before beginning your cut. Maintain steady, moderate pressure throughout the operation.
Use Tape to Minimize Splinters
A quick and simple fix is to apply painter’s tape along the cut line. While it won’t completely prevent tearout, it can reduce splintering and even preserve loose fibres for gluing back. This is especially helpful with veneered plywood, where fine layers tend to peel away.
Back It Up with Scrap Wood
Placing a scrap piece of wood directly behind your workpiece ensures the blade exits into solid material, not open air. This prevents the fibres at the edge from lifting. Whether you’re crosscutting with a mitre saw or drilling a hole, a backing board is one of the most reliable ways to prevent tearout.
Zero-Clearance Inserts
Zero-clearance throat plates are another game-changer. Whether on a table saw or mitre saw, these inserts close the gap around the blade, supporting material from below and reducing the likelihood of splintering. They can be easily made from MDF or plywood and swapped out when worn.
Practical Tips in Real Workshops
These fixes don’t require a high-end setup—just a bit of planning. Keeping a few scraps handy, replacing tape regularly, and sharpening blades can drastically improve the quality of your cuts. Even something as basic as ensuring the workpiece is flush against a backer can make the difference between a clean edge and a ruined panel.