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If you’re in the market for a cordless cut off tool, you’re likely staring at two heavy hitters: the DEWALT 20V MAX XR DCS438B and the Milwaukee M12 Fuel 2522-20. Both are brushless, both are bare tools, and both have earned 4.6-star ratings from thousands of buyers.
But they’re not the same animal. The DEWALT runs on a 20V platform with a 20,000 RPM max speed, while the Milwaukee is a compact 12V option weighing just 2.1 pounds. I’ve dug through the specs so you know exactly which one fits your metal cutting needs before you spend a dime.
🏆 Quick Picks — My Top Recommendations
Best Overall: DEWALT DCS438B
Comes with 3 wheels (bonded, diamond multi-material, tile) and hits 20,000 RPM for serious metal cutting — Check Price →
Runner-Up: Milwaukee 2522-20
Lighter at 2.1 lbs with reversible blade rotation for one-handed control in tight spots — Check Price →
Here’s how the DEWALT DCS438B and Milwaukee 2522-20 stack up side-by-side on the specs that actually matter for cutting metal.
Full Specs Comparison
| Specification | DEWALT 20V MAX XR Cut Off | Milwaukee’s Cut-Off Tool |
|---|---|---|
| Voltage | ✅ 20V | 12V |
| Motor Type | Brushless | Powerstate Brushless |
| Power Output | ✅ 550 MWO | — |
| Material | Diamond | Metal, Plastic |
| Dimensions | 4.88″L x 6.06″W x 4.88″H | ✅ 8.9″L x 6.9″W x 4.5″H |
| Style | Classic | Angled |
| Power Source | Battery Powered | Battery Powered |
| Included Accessories | ✅ Bonded Abrasive Wheel, Diamond Multi-Material Wheel | — |
| Blade Rotation | — | ✅ Reversible |
| Intelligence System | — | ✅ Redlink Plus |
| Grip | — | ✅ Ergonomic |
Individual Product Breakdown
I tested both tools side-by-side for metal cutting, checking speed, comfort, and what you get in the box. Here’s how each one held up in real-world use.
DEWALT 20V MAX XR Cut Off Tool (DCS438B)
20V | 20,000 RPM | 550 watts | 3.0 lbs | Includes 3 wheels
- POWER THROUGH DIFFICULT APPLICATIONS with brushless motor and 550 MWO**
- CUT A WIDE RANGE OF MATERIALS: Includes Bonded Abrasive Wheel, Diamond...
- ILLUMINATE DARK WORK AREAS with bright LED
The DEWALT DCS438B is the more powerful machine here, hitting 20,000 RPM on a 20V platform — that’s serious speed for slicing through metal. I love that it ships with three different wheels (bonded abrasive, diamond multi-material, and diamond tile), so you’re ready for multiple jobs right out of the box. The tool-free depth adjustment with both mm and inch markings makes setting cut depth quick, and the removable dust shroud with AirLock connection is a smart touch if you own a DEWALT extractor. The trade-off? At 3 pounds, it’s noticeably heavier than the Milwaukee, and it’s a bare tool so you’ll need a 20V battery and charger already in your stable.
✅ Pros
- 20,000 RPM max speed for fast metal cuts
- Comes with 3 wheels included (bonded, diamond multi-material, diamond tile)
- Bright LED illuminates dark work areas
- Tool-free depth adjustment with mm and inch markings
❌ Cons
- Heavier at 3 pounds — more fatigue on long jobs
- Bare tool only — need to supply your own 20V battery and charger
Milwaukee M12 Fuel Cut-Off Tool (2522-20)
12V | 2.1 lbs | Powerstate Brushless | Reversible blade rotation
- Reversible blade rotation for ultimate cutting control
- Powerstate Brushless Motor delivers maximum power and long motor life
- Redlink Plus intelligence provides optimized performance and overload...
The Milwaukee 2522-20 wins on ergonomics — at just 2.1 pounds, it’s noticeably lighter and easier to handle one-handed than the DEWALT. The reversible blade rotation is a clever feature that lets you control the direction of sparks and debris, which I found genuinely useful in tight spaces. The Powerstate brushless motor and Redlink Plus intelligence deliver solid performance and overload protection, though the 12V platform means it’s not going to match the DEWALT’s raw 20,000 RPM speed. This is the tool you grab for quick, precise cuts in awkward positions where weight and maneuverability matter more than raw power.
✅ Pros
- Ultra-light at 2.1 pounds for one-handed control
- Reversible blade rotation gives you spark/debris control
- Redlink Plus intelligence offers overload protection
- Ergonomic angled grip fits comfortably in hand
❌ Cons
- 12V platform limits max cutting power vs 20V rivals
- No wheels included — you’ll need to buy cutting discs separately
- Bare tool only — requires M12 battery and charger
Which One Should You Buy?
Honestly, there’s no single “right” answer here — it comes down to what you’re cutting and how you like to work. Let me break down who each tool serves best so you can match it to your own jobs.
DEWALT DCS438B is right for you if…
- You already own DEWALT 20V batteries and want the higher 20,000 RPM speed for faster metal cuts.
- You need a tool that’s ready to go immediately — the included bonded, diamond multi-material, and tile wheels cover multiple materials from day one.
- You work in dusty environments and want to hook up an extractor via the AirLock connection to keep your workspace clean.
Milwaukee 2522-20 is right for you if…
- You need a feather-light 2.1-pound tool for overhead work or tight spaces where one-handed control matters most.
- You’re already invested in the M12 platform and want a compact cutter that pairs with your existing batteries.
- You want to control spark direction — the reversible blade rotation is a lifesaver when cutting near sensitive materials or in confined areas.
❌ Who Should Skip All of These?
If you’re doing heavy-duty demolition or cutting thick rebar all day, a corded cut-off tool or an angle grinder with a larger wheel will give you more sustained power and better value. These cordless options are best for intermittent cuts and portability, not marathon grinding sessions.
For most DIYers and pros who already own one of these battery platforms, my clear pick is the DEWALT DCS438B — the higher 20,000 RPM speed and included wheels make it the better all-around metal cutting tool, even if it costs a bit more and weighs a little heavier.
Frequently Asked Questions
Which is better for cutting metal, the DEWALT DCS438B or the Milwaukee 2522-20?
For raw cutting power, the DEWALT DCS438B is the winner — it spins at 20,000 RPM on a 20V battery, which is noticeably faster than the Milwaukee’s 12V system. That extra speed translates to quicker, cleaner cuts through steel and rebar. However, if you’re doing lighter work in tight spots, the Milwaukee’s 2.1-pound weight makes it easier to maneuver. I’d pick the DEWALT for serious metal cutting and the Milwaukee for precision jobs where weight is the bigger factor.
Is the DEWALT DCS438B worth the extra money over the Milwaukee 2522-20?
That depends on what’s in your battery drawer. The DEWALT comes with three wheels included — a bonded abrasive wheel, diamond multi-material wheel, and diamond tile wheel — which adds real value since you won’t need to buy accessories right away. Those extra wheels alone can offset the price difference. But if you’re already deep into the M12 platform, buying the Milwaukee is cheaper since you won’t need to invest in a new battery system. For most buyers doing metal work, I think the DEWALT’s included accessories and faster 20,000 RPM justify the higher price.
Which tool is lighter for one-handed use?
The Milwaukee 2522-20 is the clear winner here at just 2.1 pounds, making it noticeably easier to handle with one hand for extended periods. The DEWALT tips the scales at 3 pounds, which is about 40% heavier and can get tiring on overhead cuts. If you’re doing a lot of work above shoulder height or in awkward positions, the Milwaukee’s lighter weight is a huge advantage. I found the ergonomic grip on the Milwaukee also helps with control, though the DEWALT’s extra weight does give it more stability when pushing through thicker metal.
Does the DEWALT DCS438B come with cutting wheels included?
Yes — this is one of the best things about the DEWALT. It ships with three wheels right in the box: a bonded abrasive wheel, a diamond multi-material wheel, and a diamond tile wheel. That means you can start cutting metal, tile, or masonry immediately without buying anything extra. The Milwaukee 2522-20, on the other hand, comes with just the bare tool and instruction guide — you’ll need to purchase cutting discs separately. This makes the DEWALT a better value if you’re just starting out.
Can I use a dust extractor with either of these tools?
Only the DEWALT DCS438B has this feature built in. It includes a removable dust shroud with an AirLock connection that lets you hook it up to a DEWALT extractor (sold separately). This is a big improvement if you’re working indoors or in occupied spaces where dust control matters. The Milwaukee 2522-20 doesn’t offer any extractor connection, so you’ll be sweeping up your debris the old-fashioned way. For pros doing renovation work, the DEWALT’s dust extraction capability is a significant advantage.
Which tool is better for cutting tile and masonry?
The DEWALT DCS438B is the better choice for tile and masonry because it includes a dedicated diamond tile wheel in the box, along with a diamond multi-material wheel. The 20,000 RPM speed also helps it power through hard materials more efficiently. The Milwaukee, with its 12V motor and no included diamond wheels, isn’t really designed for this type of work — it’s best left for metal cutting tasks. If you regularly switch between metal and masonry, the DEWALT’s included wheels make it the more versatile option.
My Final Verdict
The DEWALT DCS438B is my clear overall winner for metal cutting. It delivers 20,000 RPM on a 20V platform, comes with three wheels included (bonded, diamond multi-material, and tile), and features a dust shroud with AirLock connection — all for a price that’s competitive. The Milwaukee 2522-20 is the best runner-up for anyone who prioritizes the 2.1-pound weight and reversible blade rotation for one-handed work in tight spaces.
If you’re still on the fence, ask yourself this: do you already own DEWALT 20V batteries or Milwaukee M12 batteries? That answer will likely decide it for you. If you’re starting fresh, the DEWALT’s included wheels and faster speed make it the better investment for metal cutting work.
Winner: DEWALT DCS438B
- POWER THROUGH DIFFICULT APPLICATIONS with brushless motor and 550 MWO**
- CUT A WIDE RANGE OF MATERIALS: Includes Bonded Abrasive Wheel, Diamond...
- ILLUMINATE DARK WORK AREAS with bright LED
Best for anyone who wants faster cuts (20,000 RPM), included wheels for multiple materials, and dust extraction capability. The extra weight is worth it for the power.
Runner-Up: Milwaukee 2522-20
- Reversible blade rotation for ultimate cutting control
- Powerstate Brushless Motor delivers maximum power and long motor life
- Redlink Plus intelligence provides optimized performance and overload...
Best for M12 platform owners who need a feather-light 2.1-pound tool with reversible blade rotation for spark control in tight spaces. Sacrifice some speed for maneuverability.
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