How to Cut Aluminium

When it comes to cutting aluminium for your metalworking project, there are a few things to consider before you choose the right tool and method. The first is the scale of your project. The more aluminium you have to cut – the more likely you are to need high-powered tools.

You should also consider the specifics of the cuts you want to make. For example, a simple cutting tool isn’t the right choice if you need to work around complex angles and shapes. Either way, you’ll need to keep the specifics of your project in mind before choosing a method to cut your aluminium.

1. Hacksaw

One of the most traditional ways to cut aluminium is to use a hacksaw. A hacksaw is a common tool for wood and metalwork that consists of a singular saw blade and a large, curved handle.

The hacksaw offers a way to cut aluminium with the precision of your own hands. You’ll be able to carve out specific angles and shapes with a bit of preparation and knowledge. Its fine-toothed blade can deal with aluminium, but it is best suited for thinner cuts.

You should keep in mind that out of all the options you have, a hacksaw is the most basic of aluminium-cutting tools. It should be used for simple jobs and can be a good choice for small DIY projects.

2. Circular saw

If the scale of your metalworking project is larger, then you should consider using a circular saw. Power and precision combine with this handy tool that has been used in metalworking for generations. As far as large power tools go, it is one of the simplest – but it does require some safety knowledge and skill to use!

A circular saw should be your first choice when working with a thicker cut of aluminium – or on a larger project where you need multiple cuts.

3. Laser cutting

Sometimes you need more precision and control. This is especially true on intricate DIY projects or on commercial projects. This is why many people opt to use more sophisticated tools such as a laser cutter on their aluminium. Laser cutters work by using a focused laser beam that melts the metal. Laser cutting is a great choice for mild steels and more lightweight metals such as aluminium due to its precision and power.

4. Plasma cutting

For the most complex of projects, plasma cutting is a great solution! If you’ve never heard of plasma cutting before, you should know that it is a cutting tool that uses ionised gas to cut thick lengths of metal. While this isn’t always needed for aluminium due to its flexibility and weight-thickness ratio – there are projects where it might be required.

Plasma cutting offers you unparalleled power when dealing with thick cuts of aluminium, as well as an impressive degree of control with odd shapes or difficult patterns.

5. Mitre cutting

So, we’ve covered a series of cutting tools that can handle thick cuts and more precise angles and shapes – but what about when you have something truly challenging? If you need angled, precise cuts then you should consider getting your materials mitre cut.

Mitre cutting is perfect for awkward shapes like tube, channel, angle and others. The most common angle you’ll find with mitre cutting is 45 degrees, but this can be changed depending on the specifics of your project.

Making sure you keep safe while cutting aluminium is an important part of the process. Different cutting methods require different safety equipment and procedures, so you should always keep this in mind after selecting a method. Here are some safety measures you should keep in mind when cutting aluminium:

Protective Gear

Depending on the cutting method you choose, you may need different forms of protective gear. This includes eye protection, hearing protection, and respiratory clothing.

You should also make sure you wear suitable clothing to protect your body. This might include gloves, footwear, or general clothing. When it comes to footwear, you should always wear closed-toe shoes while working with metal.

Workspace Safety

Making your workspace safe for the cutting method you have chosen is also vital to avoid complications. No matter the cutting method, you should create a ventilated workspace that is free from clutter. This will help to prevent potential accidents from happening. You should also make sure that your aluminium workpiece is securely clamped to prevent movement during cutting.

Tool Safety

The cutting tool you choose will have its own risks associated with it. You need to make sure you familiarize yourself with the tool to make sure you understand how it works as well as its potential risks. If you’re using a hacksaw or circular saw, you need to make sure they are sharp and in good condition before starting a cut.

When deciding how to cut aluminium, you’ll need to weigh up whether it can be done yourself or you need professional assistance.

While anyone can use a hacksaw or a small circular saw to cut aluminium (with basic safety knowledge and a bit of practice), other tools require specialized knowledge and skills. Not to mention more of an investment – you might have a hacksaw in your workshop at home, but it’s unlikely you have a laser cutter or a plasma cutter.

If you’ve determined that your metalworking project requires specialized equipment, you’ll need to find experts who can help you with intricate cuts and precise angles. Thankfully, there are many different options you can choose from.