Choosing a cable cutter looks simple — until you try to cut a 400 mm² cable with a tool rated for 200 mm². An undersized cutter crushes the cable instead of cutting it, leaves a deformed end that is hard to terminate, and can damage the blades or handles. An oversized cutter is heavy and slow for everyday work.
This guide explains how to match a cable cutter to the cable you actually cut, how to read mm², AWG and MCM ratings, and when a ratcheting cable cutter is the better choice.
1. Start with the conductor size
Cable cutters are rated by the largest conductor cross-section they can cut. You will see three units:
- mm² — used in Europe, Asia and most of the world (often listed as JIS or DIN sizes)
- AWG — American Wire Gauge, used in North America for smaller cables (the larger the number, the smaller the wire; 1/0 to 4/0 are the largest AWG sizes)
- MCM / kcmil — thousands of circular mils, used in North America for cables above 4/0 AWG
Always choose a cutter whose rated capacity is equal to or larger than the biggest cable you cut regularly.
AWG / MCM to mm² conversion chart
| AWG / MCM | Approx. mm² |
|---|---|
| 2 AWG | 33.6 mm² |
| 1/0 AWG | 53.5 mm² |
| 2/0 AWG | 67.4 mm² |
| 3/0 AWG | 85.0 mm² |
| 4/0 AWG | 107 mm² |
| 250 MCM | 127 mm² |
| 300 MCM | 152 mm² |
| 350 MCM | 177 mm² |
| 400 MCM | 203 mm² |
| 500 MCM | 253 mm² |
| 600 MCM | 304 mm² |
| 750 MCM | 380 mm² |
| 800 MCM | 405 mm² |
| 1000 MCM | 507 mm² |
2. Check the conductor material and cable type
- Copper and aluminum cable — standard cable cutters are designed for these soft conductors, stranded or solid. Aluminum is softer and easier to cut than copper of the same size.
- Steel-reinforced cable, steel wire rope, ACSR or armored cable — do not use a standard cable cutter. Hardened steel strands will notch or chip the blades. Use a cutter designed for steel wire, such as a wire rope cutter.
- Cable outer diameter — the cable, including its insulation and sheath, must fit fully inside the jaws before cutting. Multi-core cables with thick insulation can be larger than the conductor size suggests, so check the outer diameter as well as the mm² rating.
3. Manual or ratcheting?
| Long-handle cable cutter | Ratcheting cable cutter | |
|---|---|---|
| How it works | Cuts in one closing stroke; force comes from long handles | Cuts in several short strokes; the ratchet holds the blades between strokes |
| Best for | Fast cutting of small and medium cables, daily installation work | Large cables, tight spaces, reducing hand effort |
| Typical range | Up to about 500 mm² with long handles | 300 mm² and above |
As a rule of thumb, a long-handle cutter is fastest for cables up to around 200–250 mm². For larger cables — or when you cut in confined spaces where you cannot open long handles — a ratcheting cutter needs much less force.
4. Look at blade material and build quality
The blades do the work. Look for forged, heat-treated alloy steel cutting heads (for example SCM440 chromium-molybdenum steel) that keep a sharp edge after repeated cuts, and a rigid body that does not flex under load. A clean, square cut makes it much easier to strip the cable and fit a lug.
5. Quick selection guide
| Largest cable you cut | Suggested type | THK models |
|---|---|---|
| Up to 100 mm² (4/0 AWG) | Long-handle cable cutter | VC-100 |
| Up to 200–250 mm² (400–500 MCM) | Long-handle cable cutter | VC-200, VC-250 |
| Up to 325 mm² (600 MCM) | Ratcheting cable cutter | VRC-325 |
| Up to 400 mm² (800 MCM) | Long-handle cable cutter | VC-400 |
| Up to 500 mm² (1000 MCM) | Long-handle or ratcheting | VC-500, VRC-500, VRC-500N |
| Steel wire rope up to Ø18 mm, or cable up to 400 mm² | Dual-purpose wire rope & cable cutter | CW400/16 |
All THK cable cutters are rated for copper and aluminum cable. Full specifications are on each product page and in our product catalog (PDF).
6. Safety tips
- Never cut live cables. Make sure the circuit is isolated and verified dead before cutting.
- Keep the cable at a right angle to the blades and do not twist the tool while cutting.
- Do not exceed the rated capacity or extend the handles with pipes.
- Keep the blades clean and replace or service the tool if the cutting edges are damaged.
Need help choosing?
Tell us the cable size, material and quantity you need — our team in Taiwan will recommend the right model and send a quotation, usually within 1–2 business days. THK Cutters manufactures cable cutters, ratcheting cable cutters and crimping tools for importers, distributors and tool brands, with OEM and private label available.
Related guide: Terminal Size Chart: JIS vs DIN vs AWG (mm² Conversion Guide)
