Expert Tips for Cutting Extruded Aluminum in 2023

Are you tired of your aluminum cutting skills being second-rate? Do you want to become the next aluminum cutting sensation among your friends? Well, then you're in luck! We have the ultimate tips and tricks that will turn you into a cutting-edge aluminum-cutting expert. Buckle up and get ready to have a laugh while learning how to cut extruded aluminum like a pro!

Cutting aluminum may seem like a daunting task, but with our help, it'll be as easy as cutting a hotdog. You don't need to be a rocket scientist to cut aluminum; you only need the right tool and a bit of knowledge. So, let's get started!

What is the best aluminum cutter saw?

The best saw to cut aluminum depends on the type and thickness of the aluminum, as well as the specific requirements of your project. Here are some commonly used saws for cutting aluminum:

• Mitre saw: A mitre saw is a versatile single or double head machine with a few features that can be used to cut aluminum extrusions and other materials at precise angles. It works well for cutting small to medium-sized aluminum pieces. It's a perfect replacement for a consumer saw because it makes faster cuts, enables increase productivity and is designed with a motor made to last. This type of saw has received great reviews and offers a bigger blade size than most consumer saws. Additionally, a mitre saw typically comes with a stable base and is built to last, ensuring long-term durability and reliability. By investing in a mitre saw, you can unlock the full potential of your workshop and take advantage of its multiple configurations. If you don't want to be left in the dust, a mitre saw is a valuable tool to consider. In our opinion, the Shark24 Rising Blade Industrial Saw offers the best value on the market in terms of its quality, features, and competitive pricing.

• Circular saw: A circular saw is another popular tool for cutting aluminum. Choose a carbide-tipped blade with a high tooth count for best results. Circular saws work well for cutting thicker aluminum sheets and plates.

• Table saw: A table saw can also be used to cut aluminum, particularly for larger and thicker pieces. Choose a blade with a high tooth count and a low RPM to prevent the aluminum from overheating and warping.

• Bandsaw: A bandsaw is ideal for cutting curved and irregular shapes in aluminum. Choose a blade with a fine tooth count and a high blade speed for best results. For industrial bandsaw cutting tool technology, great price, replacement parts, faster delivery or faster service, check out Promax Machinery.

• Chop saw: An industrial chop saw is a powerful tool that can quickly cut through thick metal pieces. However, it can create a lot of sparks and heat, so it's important to use proper safety gear and work in a well-ventilated area. 

If you're in the market for a single head saw that can cut through a variety of materials, including plastic, wood, and even brass, don't waste your time and check out The Cutting Experts or Evolution Power Tools. These companies offer a range of single head saws (with great reviews) that are designed to provide clean and precise cuts in a variety of materials. Many of these saws feature adjustable cutting angles, allowing you to make precise cuts at a variety of angles, and some also offer features like laser guides or digital displays to help ensure accuracy. They feature videos and are sorted by category. Go there to check out the details: thecuttingexpert.com

Do you need a special saw to cut aluminum?

While it is possible to cut aluminum with many different types of saws, using a saw that is specifically designed for cutting aluminum can make the job easier and produce better results. A special saw designed for cutting aluminum typically features a carbide-tipped blade with a high tooth count and a low RPM to prevent the aluminum from overheating and warping. This type of saw can help to ensure clean cuts with minimal burrs or rough edges, which can be important for certain applications. However, if you don't have access to a specialized saw, it is still possible to cut aluminum using other types of saws, such as a miter saw, circular saw, or bandsaw, as long as you use the appropriate blade and take proper precautions to avoid overheating or other issues.

What is the best saw for cutting aluminum extrusion?

While the best saw for cutting aluminum extrusion will depend on the specific requirements of your project, a mitre saw is a versatile option that can be used for a wide range of cutting tasks, including making precise angle cuts. However, a chop saw can also be a great entry-level option for cutting aluminum extrusion, particularly for those who are new to the task. A chop saw can be a more affordable option than other types of saws, and it can quickly cut through thick aluminum extrusion. However, it's important to keep in mind that typical chop saws can create a lot of sparks and heat, so proper safety gear and ventilation are essential. Blade life can be compromised if cutting fluid isn't used. Ultimately, the best saw for cutting aluminum extrusion will depend on your specific needs and budget.

What is the best blade to cut aluminum?

Here are some commonly used blades for cutting aluminum: 

• Carbide-tipped blade: Carbide-tipped blades are a popular choice for cutting aluminum. They feature carbide teeth that are resistant to wear and can easily cut through the metal without dulling quickly.

• High-speed steel blade: High-speed steel blades are another option for cutting aluminum. They are durable and long-lasting, but they may not be as effective as carbide-tipped blades for cutting thicker aluminum.

• Diamond blade: Diamond blades are a specialized type of blade that can be used for cutting aluminum as well as other hard materials like stone and ceramics. They are extremely durable and can produce a clean cut, but they can be more expensive than other types of blades.

• Abrasive blade: Abrasive blades are designed to cut through harder materials like metal and concrete. They work by grinding away at the material, which can produce a rougher cut than other types of blades. However, they can be an affordable option for cutting aluminum, particularly for those who don't have access to a specialized blade.

Ultimately, the best saw blade for sawing aluminum will depend on the specific requirements of your project and the saw technology you are using. Be sure to choose a blade that is designed for cutting aluminum and follow the manufacturer's recommendations for proper use and maintenance. The Cutting Experts and Evolution Power Tools offer a saw blade catalogue for various sawing such as steel, aluminum, and stainless steel cutting. Their blades are designed to provide clean, accurate cuts with minimal burrs and heat buildup.

Can a chop saw cut aluminum?

Yes, a chop saw can cut aluminum! However, it's important to use the appropriate blade and take proper precautions to avoid overheating the metal and causing warping or other damage.

To cut aluminum with a chop saw, you'll need a blade specifically designed for cutting non-ferrous metals like aluminum. Look for a blade with carbide teeth and a high tooth count to ensure a clean and efficient cut.

If you decide to purchase a chop saw to cut metals, it's important to take proper precautions to avoid overheating the metal. This can be achieved by using a slow feed rate, using a coolant like cutting oil or lubricant spray, and allowing the metal to cool between cuts. The guys at The Cutting Experts will hook you up with a great manual chop saw or automatic chop saw.

High speed sawing for cutting aluminum?

When using a circular saw to cut aluminum, it's important to use the appropriate blade and speed to avoid overheating the metal, which can cause warping and other issues. Here are some general guidelines for choosing the right speed for cutting aluminum with a circular saw: 

• Blade speed: Look for a circular saw with a maximum blade speed of at least 3500 RPM. This will ensure that the blade can cut through the aluminum efficiently without overheating the metal.

• Tooth count: Choose a blade with a high tooth count, to ensure a smooth and clean cut.

• Feed rate: When cutting aluminum with a circular saw, it's important to maintain a consistent feed rate to prevent overheating and ensure a clean cut. Start with a slower feed rate and gradually increase the speed as you become more comfortable with the tool.

• Coolant: To further prevent overheating, consider using a coolant like cutting oil or lubricant spray. This can help to reduce friction and keep the blade and aluminum cool during cutting. 

Overall, it's important to choose a circular saw with a suitable blade and speed, and to take proper precautions to avoid overheating the metal. Be sure to follow the manufacturer's recommendations and use appropriate safety gear, to protect eyes and ears, if you don't want to pay the price when using a circular saw.

What are some great accessories to consider?

When purchasing a saw, there are several accessories that can improve its performance and efficiency. Here are some great accessories to consider: 

• Entry and exit tables: These tables can provide extra support for longer pieces of material, making it easier to cut them accurately and safely.

• Pneumatic clamps: Pneumatic clamps can hold the material securely in place, preventing it from moving during the cutting process. This can help to ensure clean and accurate cuts.

• Automatic stop: An automatic stop can be set to stop the saw at a specific point, allowing for consistent cuts and reducing the risk of human error.

• Material pusher: A material pusher can help to move the material through the saw, making it easier and safer to use, particularly for larger or heavier pieces.

Other accessories to consider include laser guides for improved accuracy, dust collection systems for cleaner and safer working environments, stand for stability and digital displays for precise measurements.

When choosing accessories for your saw, it's important to consider the specific needs of your project and the materials you'll be working with. Be sure to choose high-quality accessories from reputable manufacturers and follow all manufacturer recommendations for safe and effective use of the tool.

Is it an error to use band saws to do the job?

It's not an error to use band saws to cut extruded aluminum. Band saws can be an effective tool for cutting aluminum, particularly when working with thicker or larger pieces of material. However, it's important to use the appropriate blade and take proper precautions to avoid overheating the metal and causing warping or other damage.

To cut aluminum with a band saw, you'll need a blade specifically designed for cutting non-ferrous metals like aluminum. Look for a blade with carbide teeth and a high tooth count, (such as 10-14 per inch), to ensure a clean and efficient cut.

It's important to take proper precautions to avoid overheating the metal. This can be achieved by using a slower blade speed, using a coolant like cutting oil or lubricant spray, and allowing the metal to cool between cuts.

Overall, band saws can be an effective tool for cutting extruded aluminum, particularly when working with thicker or larger pieces of material. Just be sure to use the appropriate blade and take proper precautions to avoid overheating the metal and causing damage.

To conclude...

Cutting extruded aluminum can be made easy and efficient with the right tool and knowledge. Whether you're working on a DIY project or a professional job, choosing the right saw, blade, and accessories can make all the difference. By following the expert tips and tricks outlined in this article, you'll be able to achieve clean, precise cuts in no time. Whether you're using a chop saw, mitre saw, or band saw, make sure to take all necessary precautions to ensure your safety and the longevity of your equipment. So don't wait any longer - get yourself a high-quality metal cutting saw and start putting our tips to use!