Best saw for cutting aluminum. Cutting aluminum circular saw

How To Cut Aluminum? | Aluminum Cutting Guide 2023

Would you like to cut aluminum sheets or thicker parts? I frequently find myself in situations where cutting aluminum necessitates a more manual approach. To achieve safe cutting operation you need to have some really good skills to handle part and saw during the cutting process. Otherwise, results can be unsafe and intimidating.

We all use Aluminum alongside the CNC part manufacturing to make complex shiny aerodynamic parts or a vacuum mold. Its light weight allows us to use aluminum sheets everywhere. Sometimes you need to have just a piece of block Aluminum or a 3mm Aluminum sheet to get the job done. I guarantee you are not alone on this.

Both thin aluminum sheets and thick 6000 and 7000 series aluminum materials have a wide usage area in the industry in such areas as automobile, and molding, componentry. In this article, I’m going to explain and teach you how to cut aluminum with ease and safely.

Things to consider before starting cutting.

The choice of the cutting method depends on your material`s type. Because thick and thin materials can be cut with different cutting methods. Also, the proper method for a thick material can be dangerous and expensive compared to cutting a thin sheet of aluminum.

Most Common Saws To Cut Aluminum.

Since aluminum material is easily cut and machinable it can be easily cut with almost any cutting tool. Especially industrial metal cutting shears and circular saws are very suitable for these works.

In my experience, circular saws have proven to be more useful. Because industrial shears tend to bend thin sheets during cutting. Also, circular saws can grab and destroy thin sheets easily.

So this process needs ultra care, I remember that also I destroyed a lot of materials because of these reasons.

How to cut any thickness aluminum in a safe efficient way in 6 steps?

Before going through the aluminum cutting methods for thick and thin aluminum I thought a common way can be helpful for you to understand the whole process. So you can transform these skills in further sections.

Important Safety Notice!

In this post you see some instruction to cut aluminium. So before go ahead please take this safety steps first.This steps must be taken for all mechanical handcraftsman jobs.Be sure for all jobs you take this steps before you start.

1-Wear Safety Glasses before starting any job.

3-Make sure before using any hand power tools you clamped job properly.

4-Always take a proper position to use power tools. Your arms must move freely,strongly to target.

Firstly, you must make sure that you are safe before starting any work. Eye protection is especially important, refined aluminum chips can stick to your eyeballs easily.

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You can start by getting full-coverage goggles, earplugs to help block out noise, and a suit that fits the cut. Some people would rather wear masks that cover the whole face and protect it than glasses.

Sketching the desired shape on the aluminum piece before cutting can significantly improve the accuracy and quality of the cut. Use any kind of ruler to make the marking process easier.

To cut thin aluminum sheets, opt for a wood saw with a carbide tip. Ideally, select a blade designed for making fine cuts. Small saw teeth will be less likely to grab material dangerously. If you’re uncertain about the appropriate cutting oil to lubricate the blade, consult an expert. Once you determine the suitable oil, apply it generously to the saw’s blades.

Attach the piece of aluminum you want to cut to the saw and make sure your fingers are not too close to the blades. In this way, you will keep your fingers from getting hurt.

Move the blade through the aluminum or the aluminum through the blade very slowly. Make sure that the speed of the wood cutting is faster than the speed of the blade. Also, try to stay away from the area where the saw hits the wood behind it. A jigsaw is the best tool to use if you want to make circular cuts in aluminum.

How do you cut a thin piece of aluminum?

Tin shears can be used to cut aluminum that is 1 millimeter thick and needs to be cut into flat pieces. If the aluminum is between 2 and 3 millimeters thick, you can cut it straight with a. If you want to cut curved pieces, the jigsaw will make too much burr. With a file, it is possible to fix this problem. The steps for making these cuts are: draw, cut, and file. These three things will help you make your cut exactly how you want it.

Aluminum sheets.

Aluminum sheets are very useful for decorations and making chassis of cars with progressive molds.

These days most new products heavily rely on aluminum sheets. It is a very attractive material.

How do you cut an aluminum sheet?

You might think that to cut an aluminum sheet to size, you need. Luckily, cutting aluminum sheets is easy to do with a jigsaw or a regular woodcut saw. You will need to buy the right blade for the saw, though. Most of the time, circular blade saws, like lowering saws or table saws, are better than straight blade saws for cutting aluminum.

1-Use the ruler to figure out how long you want to cut the aluminum.

2-Use the marker to make marks on the aluminum. You will cut along this line, so make sure it is straight and goes in the direction you want to cut.

3-Attach your saw to the edge of the sheet metal and let it rest there. If you are using a hacksaw, you will need to put the sheets on a pair of saws so that the saw blade can cut through the metal without anything under it.

4-Make sure the blade is not touching the metal sheet, and then turn on the saw.

5-Slowly move the saw into the metal sheet until it starts to cut. Keep going forward, but don’t put too much pressure on the saw blade. If you put too much pressure on the aluminum, it will get stuck or burn, and your saw and sheet will be damaged.

6-Wear gloves and a face mask when you do this to protect your hands and face from the hot aluminum chips that will come out of the cut.

How to cut a thick sheet of aluminum?

For cutting boards thicker than 3 millimeters, you can also use a spiral instead of a carbide-tipped wood saw. If you need a curved cut with fine craftsmanship in such thicknesses but don’t think you’re ready, you can get help from professionals. So, your aluminum part will be cut the way you want, and you will be safe from any accidents that could happen.

Pro tips for cutting thin aluminum sheets.

Tip-1: Use high tooth count saws (with smaller teeth). This will produce finer chips, and the blade saw will not grab and bend the sheet.

Tip-2: Use cutting oil to prevent heat buildup which will deform the sheet. Also, oil or coolant will evacuate chips from the blade, so chips will not melt and grab the sheet.

Tip-3: Always have a rigid base to lay aluminum sheet, and during the cutting always move your blade to the edge of this base(or flat workbench). This will prevent the sheet from getting bent and grabbed by the saw.

Tip-4: Do not forget, you can easily cut thin aluminum sheets with shears, in this case, you will avoid sheet holding and saw machine using process.

Pro tips for cutting thick aluminum sheets.

Tip-1: Use low-tooth count and positive rake-angled saws (with bigger teeth). Since thick aluminum engages most of the saw`s teeth there is not too much risk to grab of grabbing material. Bigger teeth will cut more material.

Tip-2: Take extra care for clapping, because thicker material requires the harder human push of the saw and this will produce a lot of stress on your clamps.

Tip-3: High pushing power can lead you to go our cutting sketch, so keep your eye on it.

Tip-4: Use cutting oil or coolant to evacuate chips and cool down part and blade.

Tip-5: Take frequent breaks to prevent the blade from overheating and avoid fatigue. This is especially important when cutting thicker materials, which can take longer to cut through.

Tip-6: Make sure the saw is securely clamped to the workpiece before cutting.


This article provides a comprehensive guide on how to safely and efficiently cut aluminum. We explained the different saws that can be used to cut aluminum, including circular saws, Band saws, and jigsaws.

Also, there are step-by-step instructions on how to use a wood saw, a jigsaw, or a hacksaw to cut aluminum. You will find a handful of pro tips for cutting thick and thin aluminum. Also others such as using high-tooth count saws and cutting oil to prevent heat buildup.

Overall, this guide is valuable guide for anyone who works with aluminum in a CNC workshop or any kind of mechanical workshop. This will help you to get your skills level up and going to make sure you are safe on your journey.

By Isaac Aloyan

Isaac Aloyan is a talented mechanical engineer with a background in machinery design and manufacturing. He completed his diploma from the Department of Machinery Design and Manufacturing at Kocaeli University and also graduated from Level 7 NZDE Mechanical Engineering at Manukau Institute of Technology (M.I.T). Isaac has developed strong expertise in various areas of mechanical engineering, including CNC programming and machining, vacuum mold design and production, manual machining, CAD and CAM, and thermoforming machine design and production. Also, he has educator experience in the area of CNC machinery and programming and mechanical design. With two decades of experience under his belt, Isaac has established a website called to share his knowledge and help others who are interested in the field of mechanical engineering. The site is likely to feature a wealth of information, resources, and tips for those looking to learn about CNC machines, machining, mold production, and more. It is a testament to Isaac’s dedication to the field and his commitment to helping others excel in sub-domains of mechanical engineering like design and manufacturing.

The importance of choosing the right saw to cut aluminum extrusions

Cutting non ferrous metals like aluminum is a task that requires the right tool for the job. Using the wrong saw or electric power tool can result in damage to the material, unsafe working conditions, and poor quality cuts. Choosing the best saw to cut thin aluminum or an aluminum plate is crucial to achieving the desired outcome. In this blog post, we will explore the various types of saws available in the market and the factors to consider when selecting the right saw for your aluminum cutting needs.

Brief overview of the different types of saws available in the market

There are several different types of saws on the market, each designed for specific purposes. Some saws are ideal for cutting wood, while others are better suited for cutting metal. When it comes to cutting aluminum, there are several options to choose from, each with its own advantages and disadvantages. In the following sections, we will provide an overview of the different types of saws available to cut aluminum and their features to help you make an informed decision.

Selecting the best saw for cutting aluminum

When choosing the best saw to cut aluminum, it is important to consider several key criteria to ensure that you get the most accurate and efficient cuts possible. These criteria include:

  • Accuracy of the cut: One of the most important factors to consider when selecting a saw to cut aluminum is the accuracy of the cut. You want a saw that can provide precise and clean cuts, without any jagged edges or burrs.
  • Cutting speed: Another important criterion is cutting speed. You want a saw that can cut through aluminum quickly and efficiently, without causing any heat buildup or distortion.
  • Versatility in cutting angles and profiles: Depending on the project, you may need a saw that can make cuts at different angles or profiles. Look for a saw that offers a wide range of cutting options to suit your specific needs.
  • Safety features: Safety should always be a top priority when working with power tools. Look for a saw that comes with safety features such as blade guards, anti-kickback devices, and overload protection.
  • Durability and reliability: You want a saw that is built to last and can withstand heavy use without breaking down. Look for a saw made from high-quality materials and backed by a strong warranty.
  • Ease of use and maintenance: Finally, you want a saw that is easy to use and maintain. Look for a saw that is lightweight, well-balanced, and comfortable to hold, with features such as tool-free blade changes and easy-to-access components for cleaning and maintenance.

Comparison of different saws to cut aluminum

When it comes to cutting aluminum, there are several saws available in the market. Let’s take a closer look at some of the most popular options:

  • Cobra16 Portable Cutting Machine (16-inch circular saw blade): This saw is ideal for those who need to make precise cuts on site. It’s portable and can easily be transported from one location to another. However, it doesn’t come equipped with a cooling system.
  • Manual Cobra16 (16-inch circular saw blade): This saw is designed for manual operation and is perfect for those who prefer a more hands-on approach. It’s also equipped with a cooling system to ensure the metal cutting blade stays lubricated and doesn’t overheat.
  • Automatic Cobra16 (16-inch circular saw blade): This saw is similar to the manual version, but it’s equipped with an automatic cutting feature. This is ideal for those who need to make multiple cuts quickly and efficiently.
  • Shark16 (16-inch circular saw blade): The Shark16 is a rising blade miter saw designed for industrial use. It comes equipped with a cooling system to ensure the metal cutting blade stays lubricated and doesn’t overheat. It’s also able to make precise cuts at various angles, making it versatile for different cutting needs.
  • Shark20 (20-inch circular saw blade): Similar to the Shark16, the Shark20 is a rising blade miter saw designed for industrial use. With a larger blade size, it’s able to handle thicker pieces of aluminum. It’s also equipped with a cooling system and can make precise cuts at various angles.
  • Shark24 (24-inch circular saw blade): The Shark24 is the largest of the Shark series saws, with a 24-inch blade. It’s designed to handle even thick aluminum and is ideal for manufacturing production. It’s equipped with a cooling system to ensure accuracy and reliability with each cut. One unique feature of the Shark24 is its cover, which opens automatically after each cut and closes automatically before each cut, making it more ergonomic for the operator and saving time by eliminating one operation that the operator doesn‘t need to do anymore.

It’s important to note that all of these saws are designed to withstand manufacturing production. Additionally, all of the saws (except for the Cobra16 Portable Cutting Machine) come equipped with a cooling system to lubricate the metal cutting blades, preventing them from overheating and ensuring straight cuts every time. Ultimately, the best saw to cut aluminum extrusion will depend on your specific needs and preferences, as well as the scope and frequency of your cutting tasks.

Safety should always be a top priority when operating machinery.

Safety is a critical aspect to consider when working with any type of machinery, including circular saws for cutting metal, cutting thin aluminum or cut aluminum extrusion. The Cutting Experts prioritize safety by offering saws equipped with several safety features.

One of the most important safety features in a chop saw is a blade guard. All saws offered by The Cutting Experts have a blade guard to protect the operator from the spinning carbide tipped blade. The miter saw Shark24 also has a cover equipped with a safety sensor that opens automatically after each cut and closes automatically before each cut. This feature makes it more ergonomic and saves time by removing one operation that the operator doesn’t need to do anymore.

Another essential safety feature in a saw is the cooling system. Most of the aluminum saws offered by The Cutting Experts come equipped with a cooling system to lubricate the carbide tipped blades with low viscosity cutting oil, refraining them from overheating and making nice cuts every time. Heat build up of the saw blades can cause them to warp, and in extreme cases, the rotating blade can break or fly off the saw, posing a significant risk to the operator.

In addition to the safety features on the saws themselves, it is essential to follow proper safety protocols when using any saw. Some general safety tips when working with saws for cutting aluminum include:

  • Always wear protective equipment (PPE), wear safety goggles, hearing protection, and wear gloves to protect yourself from any flying debris or noise.
  • Make sure the saw is properly plugged and grounded and to prevent electrical hazards.
  • Always use the correct carbide blade for the material being cut and ensure that the blade is properly installed and tightened.
  • Make sure the thick metal, the non ferrous materials or the aluminum piece being cut is secure and properly clamped to prevent it from moving while cutting.
  • Avoid wearing loose clothing or jewelry that can get caught in the saw.
  • Always follow the manufacturer’s instructions and safety guidelines.

Investing in an industrial saw may be initially more expensive than purchasing a saw at a hardware store. However, it is important to consider the long-term benefits and cost savings that come with investing in a high-quality industrial saw. Not only do these saws offer superior precision and cutting capabilities, but they also come equipped with advanced safety features that minimize the risk of accidents and injuries. Ultimately, investing in an industrial saw is a Smart choice for businesses looking to maximize efficiency, productivity, and safety in their operations.


Recommendation for the best saw to cut non ferrous metals like aluminum

In conclusion, choosing the right saw to cut aluminum can greatly affect the quality of the final product, as well as the efficiency and safety of the metal cutting process. In this article, we have discussed the criteria for selecting the best saw for cutting aluminum, compared several different saws in the market, and listed the pros and cons of each.

Based on the criteria and comparison, we recommend the Shark24 as the best of miter saws used to cut aluminum, particularly for industrial settings. Its large blade size, rising blade, miter saw design, safety cover, and automatic operation make it a versatile and efficient option to cut aluminum at various angles and profiles, while also prioritizing safety and ergonomics for the operator.

However, it’s important to note that the best saw to cut aluminum ultimately depends on individual needs and budget. For those who prioritize portability and flexibility, the Cobra16 Portable Cutting Machine may be the best option. Meanwhile, the Manual and Automatic Cobra16 saws offer more affordability and simplicity, albeit with some sacrifices in accuracy and versatility.

It’s also worth considering the long-term cost-effectiveness of industrial saws like the Shark24. While they may require a higher upfront investment compared to saws found at hardware stores, their durability, reliability, and precision can save businesses time and money in the long run. Additionally, the Cutting Experts offer a 3-year warranty on all their saws, which is the best in the industry, providing peace of mind for those investing in industrial saws.

Final thoughts and tips for choosing the right saw for your needs.

Before making a final decision on which saw to purchase, it’s important to consider other aspects beyond the criteria discussed in this article. These may include the size and thickness of the aluminum to be cut, the frequency and volume of cutting, the saw blade, level of operator expertise, and the availability of maintenance and repair services. By taking these factors into account, businesses can make an informed and efficient decision on which saw to invest in.

In conclusion, choosing the right saw for cutting aluminum is a crucial decision that can greatly impact the quality, safety, and cost-effectiveness of aluminum material in a business’s operations. By carefully considering the criteria, comparison, and individual needs, businesses can select a saw that maximizes their efficiency and profitability, while also prioritizing safety and quality.

Cutting Aluminum With a Miter Saw: All You Need to Know

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Handling aluminum may be tricky because it is not the most robust material. However, you cannot just use any tool to cut it since you may damage it and waste material. Many tools are available to cut aluminum, but today we’ll find out if cutting aluminum with a miter saw is worth it.

Will a Miter Saw Cut Aluminum?

A miter saw is one of the best tools for cutting aluminum. Its design allows it to clamp the aluminum and perform precise cuts with the rotating blade held by the handle. Thus, a miter saw will enable you to cut aluminum accurately while remaining safe and user-friendly.

However, specific considerations must be made, such as the metal volume and the project requirements. You must also be cautious about the type of blades you use.

Type of Miter Saw to Use to Cut Aluminum

According to our woodworkers and tool experts, you can use any type of miter saw for cutting aluminum, but for best results, use a 12-inch sliding compound miter saw.

A 12-inch sliding compound miter saw is the ideal solution for many woodworkers, contractors, and homeowners who need to cut aluminum at different angles.

Which Blades Can You Use to Cut Aluminum?

Circular Blades

These blades perform best when working with tilting angles to cut aluminum into desired shapes.

Sharp Cut Blades

If you want sharp cuts to create a perfect piece, sharp-cut blades are best.

Razor Blades

Cutting aluminum with razor blades will provide high-precision cuts.

Coarse and very coarse cut blades

These blades provide abrasive cutting to aluminum, allowing for fine finishing.

Cutting Angles for Aluminum Using a Miter Saw

Our woodworking experts recommend clamping for mitered, beveled, and compound angle cuts because it can be a little cramped for hand space with the blade tilted. Check out this calculator for compound angle if you want to calculate your compound angle cuts more accurately.

In addition, depending on your angle, the aluminum will push or pull. Clamping will result in cleaner, straighter cuts and help prevent serious injury.

If you’re working with small items or need to cut angles, don’t do it with both edges down like an inverted V because the angles will undoubtedly be crooked.

However, if you’re working on something too large for your saw, like cutting a 3′′ angle with a 7-1/4′′ blade, and only need straight cuts, this can be an excellent way to get the reach you need to cut it in a single chop.

What is a Circular Saw?

A circular saw is an electrical saw that is equipped with a blade that spins around an arbor to cut different materials. Originally invented to cut logs, this power tool may be hand-held or mounted to a machine and can be used to cut other materials such as metal and plastic depending on the saw blade. Circular saws provide users with high performance at an affordable price, making it a highly demanded alternative to wet saws and angle grinders.

As compared to cutting wood, cutting metal is trickier and can be more dangerous. Metal cutting is more akin to abrasion as compared to chipping away large chunks of wood and this will result in tiny pieces of hot metal shards flying about. Wearing a face shield, gloves are recommended when using a circular saw to reduce the risk of injuries.

How to use a Circular Saw?

In addition to face and hand protection, appropriate clothing with long sleeves should also be worn to minimise cuts and burns from the flying shards of hot metal. Selecting the right blade for the job will also assist you in cutting metals with more efficiency and ease. The metal workpiece should also be secured down with clamps and should hang at the edge of the cutting blade.

Marking the workpiece will also serve as a guide to ensure clean cutting finishes in accordance to your specifications. Once you are ready to cut, align the blade to the marking and slowly and carefully power on the circular saw and slide the blade into the metal. As you cut, frequently apply cutting fluid to help reduce heat and friction which in turn results in a cleaner cut.

Difference between HSS TCT Circular Saws

To choose the right blade for the job, one must consider the material of the metal workpiece. There are two main types of metals, ferrous metals which contain iron and non-ferrous metals such as aluminium and copper that do not have iron.

Tungsten Carbide Tipped (TCT) saw blades have teeth that are made of an alloy steel body with tungsten carbide soldered onto the tips of the teeth. The alloy body is typically made from durable materials that are wear-resistant such as chrome vanadium steel that has undergone heat treatments to obtain a rating of 38/42 on the Rockwell Hardness C Scale (HRC). The tungsten carbide itself has a HRC rating of 98 that makes it extremely hard as a higher number will indicate a stronger steel.

Kinkelder has a wide range of TCT saw blades that can cut through solid steel, steel bars and tubes. To view the whole list of Kinkelder TCT circular saw blades, click here.

Kinkelder TCT Champion Series

The Champion SL saw blade combines the performance advantages of Cermet with the latest PVD coating technology.

Equipped with a new carbide grade, PVD coating, body design, and tooth geometry to improve chip flow.

Developed for the high-performance cutting of thin and medium wall drawn tubes and high tensile tubes on high-end cut-off machines.

Kinkelder TCT Solid CX Series

PVD coated carbide tipped CX 1 saw blade developed for cutting solid steel with tensile strengths between 700 – 1,500 N/mm2 at very high production rates.

Carbide tipped and PVD coated for very fast cutting and good surface finish.

CX 7 is a Cermet tipped saw blade dedicated to cut low to medium strength carbon steel.

  • Cutting solid materials with a tensile strength up to 800 N/mm2
  • Cutting speed: 180 – 120 m-min (D 25mm – D 100mm medium tensile).
  • Tooth load: 0.08 – 0.06mm/tooth (starting value).

Kinkelder TCT Tube CX Series

Carbide tipped saw blade for efficient cutting of soft and hard tubes with minimum vibrations.

Carbide tipped and PVD coated for perfect surface finish and burr-free tube ends.

The CX 5 saw blade has been specifically designed to cut thin-walled tubes.

  • Cutting steel tubes with a tensile strength between 600 – 1500 N/mm2
  • Cutting speed: 500 – 180 m/min (LCL= 15mm low tensile – LCL 80mm high tensile
  • Cutting less stable, high hardness hollow sections on high performance machines
  • Cutting speed: 280 – 180 m/min (LCL= 15mm, high hardness – LCL 30mm, tensile strength 1200 N/mm2.
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High Speed Steel (HSS) is another type of saw blade for application in cutting metals. These saw blades are heat treated and hardened to a 64/65 HRC rating for ferrous metals and a 58/60 HRC rating for non-ferrous metals. These saw blades also have special wear resistant Titanium coatings such as Titanium Nitride (TiN) or Titanium Aluminum Nitride (TiAlN).

To view all Kinkelder HSS circular saw blades, click here.

best, cutting, aluminum, circular

Kinkelder HSS Fusion Series

Versatile applications and ideal for cutting stainless steel and any alloyed steel which have the sticky or gummy properties where other regular blades will get stuck or chipped.

Fusion 2.0 saw blades can be used for cutting medium to high tensile carbon steel on extremely demanding applications.

Kinkelder HSS X-treme Series

The X-treme series offers an optimized surface finish, low variations in blade thickness, and a small side runout. The NX coating is designed for cutting stainless steel but also can be used for dedicated steel cutting applications.

Kinkelder X-treme 2.0 saw blades offer a stable and highly accurate solution when cutting high tensile steel tubes and profiles on a very high performance level.

  • Cutting steel tubes and profiles with a tensile strength up to 1000 N/mm2
  • Suggested cutting speed: 120 – 260 m/min
  • Feed: 0.04 – 0.22 mm/tooth.

With a higher HRC rating, TCT saw blades can run at faster speeds as compared to HSS saw blades and cut harder metals at higher speeds as there is a high resistance to heat and wear. HSS saw blades typically run at a surface speed less than 350 surface feet per minute (SFM). On the downside of having a high level of hardness, both TCT and HSS saw blades are brittle and show little resistance to shock, with TCT blades having lesser resistance than HSS blades.

If you wish to find out more about Circular Saws, feel free to contact us for a consultation.

  • Circular saw. Wikipedia. Retrieved 22 July 2021, from
  • Angle grinder. Wikipedia. Retrieved 22 July 2021, from
  • Rockwell scale. Wikipedia. Retrieved 22 July 2021, from
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