Whether you’re a craftsman looking to pursue a business in metalworking, or a hobbyist planning on upcycling old goods into new purposes, you’ll probably end up working with a variety of different metals. Today we’re going to look at working with aluminum, and ways that you can cut it at home. But before we begin, a note of safety. Aluminum can be very dangerous to cut, especially as the metal gets thicker and has a higher chance of spitting shreds and toxic dust. Always wear a mask or respirator in addition to standard goggles and gloves, and for projects needing difficult cuts on thick metal such as curved or round cuts of aluminum plate, consider seeking professional services or suppliers instead.
Mechanical Blades
Aluminum sheets, when thin enough, can be cut by metal or fiberglass reinforced blades. However, precautions must be made in order to deal with the specific properties of aluminum, such as its tendency to scratch and dent. Additionally, the metal may dull the blade or pieces may lodge inside and damage the equipment, so work with caution. Circular or band saws, as well as a jigsaw cutter with the base padded with duct tape, will be able to cut through most sheets or thin aluminum plates. Round edges especially are good with a jigsaw cutter, but always watch out that the metal doesn’t heat up so much that it melts.
Manual Blades
Table mounted shears are a good choice for cutting metals as well, and with enough muscle can be used to cut thicker sheets or plates than mechanical blades. Additionally, with a lowered risk of high powered shards and dust, using manual may be the overall safer option. However, using hand snips or manual tools in general with take considerably longer than power tools, and may result in much rougher edges.
