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This article is written because I've seen many people encounter difficulties when cutting aluminum sheets.

Generally speaking, anything considered a high-performance wood tool can also be used to cut aluminum sheets.

However, there are exceptions. Let's start with some ideal tools suitable for most applications, then introduce some tools for specific applications, and finally share some tips and tricks.

Band Saw

Of course, a band saw makes the list, but it's not always the ideal tool. It's best suited for thick sheets, about half an inch or thicker.

The advantage of a band saw is that it can handle very thick sheets well—I once cut through an 8-inch thick plate without any issues.

When cutting aluminum on a band saw, you need to increase the blade speed to 250 feet per minute. If your saw has variable speed, consult the chart. Usually, you can simply move the belt to different-sized pulleys.

As for the blade, make sure there's enough space between the teeth. The distance between the teeth is referred to as TPI—teeth per inch.

The ideal TPI for cutting thick aluminum sheets is 10-14. Technically, anything will eventually cut through the sheet, but this is where you'll see the best performance.

If the TPI is too small, there's a high risk of aluminum chips clogging the blade. If the TPI is too coarse, the cutting speed will slow down due to fewer teeth engaging and removing material. It's better to lean towards being too coarse.

In any case, the main issue you want to avoid is blade clogging. Be sure to use a coolant or light oil like WD-40 to lubricate the cut and prevent chips from clogging the blade.

Circular Saw

This is actually one of my preferred methods for cutting aluminum. It's extremely fast, and if you can keep it steady, it leaves a nice, clean cut.

However, this method has more safety hazards, so let's address those first. It's always good to keep your fingers and face at a safe distance.

First, if possible, clamp the plate down. Using C-clamps to secure the aluminum to the table is a good way to keep it stable. You might want to place some wooden blocks between the table and the plate to prevent damage to the table.

This is especially important if your table is made of steel.

The chips can come out fast and hard, so safety glasses won’t provide enough protection. Switch to a full-face shield (preferably anti-fog, to prevent chips from entering from the sides and top).

Wearing gloves is also a good idea. I usually just wear a pair of welding gloves, as aluminum can be sharp.

Okay, that should keep you safe.

Now, for the blade, make sure to use a blade with carbide teeth. Circular saw blades designed for non-ferrous metals like aluminum have a lot of teeth.

This actually helps keep the saw stable. Fewer teeth on the circular saw blade can lead to... pain.

Spending a little money on a proper blade is really worth it. Spending about $20 on a good tool makes sense. The cuts will be cleaner, and it's safer to operate.

This saw blade works well. It has high-quality carbide on the teeth, so it's less likely to chip. It also has other features like the appropriate tooth angle and blade thickness that improve cutting performance.

You’ll definitely want to buy some lubricant. WD-40 works well. You can also buy wax sticks, which last longer.

If you don’t use lubricant, the saw is likely to clog and damage the blade.

This is very effective for things like diamond plate, but I've cut through 4-inch thick aluminum (which must be cut from both sides to reach a sufficient depth) with great results. It's a handy trick for objects that a band saw can't cut.

Jigsaw or Reciprocating Saw

Clearly, a circular saw is great for straight cuts but not for curved cuts. Depending on how tight the curves are, either a reciprocating saw or a jigsaw is suitable for the job. Both have their pros and cons. The reciprocating saw has a longer stroke and more power, allowing for faster cuts.

A jigsaw can make tighter turns. In fact, I've found that using a jigsaw often allows for straighter cuts on thin sheets. It's more ergonomic and less aggressive, making it less likely to wander.

These tools don’t work well for thick sheets. Doing anything over 3/16 inch or 1/4 inch can become quite challenging. Obviously, make sure you're using blades meant for metal, not wood. I've found that wax works better than light oil for these tools because it stays on the blade longer.

Tips and Tricks

If you want to make truly straight cuts, use a guide. I like to clamp a piece of flat steel to the board so I can push the circular saw along the straight edge. A 2x4 or a straight piece of wood works too. It keeps the blade straight, resulting in a very clean cut.

The blade is also less likely to bind or bend. Wax can lubricate the blade for a longer time, while spraying oil is more convenient. I’m not talking about candle wax. Buy a proper metal-cutting wax to keep on hand. The advantage of WD-40 is that you can use it for almost everything, so you should already have some on hand.

Use a Quality Circular Saw

Unless you’re looking for a reason to upgrade your existing tool. If that’s the case, I understand.

The reason is that cutting aluminum generates more vibration compared to wood. This puts more wear on your saw. If it's not tight and sturdy, your saw may not last long.

Basically, when you're cutting aluminum, don’t expect a $20 saw to last long. Keep in mind that if you’re only making a few quick cuts, you should be fine. Use tape to cover anything you don’t want to scratch.

Debris can scatter everywhere, and sliding them along a nice brushed aluminum surface can make it look unsightly. If you want to keep the surface looking nice, pretty, and scratch-free, use masking tape to protect it.

If you’re cutting diamond plates, place the patterned side down. Position the saw base on a flat surface rather than on the uneven diamond pattern. This will make it easier.

Clamp it down! I know I mentioned this before, but it's worth reiterating. Clamp the aluminum to the workbench so it doesn’t bounce around. Aluminum sheets produce a lot of vibration compared to wood, so it's worth spending a few extra minutes setting it up for better cutting.