How to Cut Aluminium

Welcome to our definitive guide on how to cut aluminium, brought to you by the team here at Salamander Fabrications. We’re here to help with your project in any way that we can, whether you need a sheet metal contractor to help facilitate your project, or just some tips and advice on how to cut aluminium sheet. 

Aluminium’s lightweight strength, corrosion resistance, and versatility make it an extremely popular material. It is used in everything from garden furniture to commercial vehicles and architectural features. But its unique combination of properties also means that knowing how to cut aluminium accurately and efficiently is essential, whether you’re a DIY hobbyist, tradesperson, or working on an industrial scale. 

In this comprehensive guide, we’ll discuss the best ways to cut aluminium sheet, the specialist tools and techniques available, and the fabrication processes that ensure your finished product looks and performs as it should.

Techniques for how to cut aluminium sheets

Aluminium sheets are available in a huge range of thicknesses, from ultra-thin foil to sturdy multi-millimetre plates. When it comes to the methods of how to cut aluminium sheet, the one you choose will depend on several factors. This includes the thickness and type of aluminium, the level of accuracy needed, and the tools you have at your disposal.

Picking the right technique not only ensures a neat, clean cut but also minimises material waste and reduces the risk of unwanted damage. This is especially crucial for parts that need to look sharp or fit together precisely.

Below, we’ll break down the most effective methods for cutting aluminium sheet, along with expert tips to help you achieve the best possible finish every time.

Laser cutting

Laser cutting services have revolutionised the metal fabrication industry, offering incredible precision and control that simply cannot be matched by manual tools. This method uses a focused laser beam to heat and melt through aluminium sheets along a pre-programmed path.

Advantages:

• Exceptional accuracy for intricate shapes
• Minimal material distortion and clean, burr-free edges
• Suitable for large scale or repetitive projects

Considerations:

• Requires specialist machinery and proper ventilation
• Best suited to lightweight metals and thin to moderately thick aluminium sheets

Ideal for:

• Architectural features
• Bespoke signage
• Detailed brackets
• Any project where tight tolerances or a smooth finish are required

Plasma cutting

Plasma cutting is another powerhouse of metal fabrication, ideal for tackling thicker sections of aluminium or making complex shapes where brute force and flexibility are needed. It works by blasting ionised gas (plasma) at extreme temperatures through a small nozzle, effectively slicing through metal.

Advantages:

• Powerful enough for thick aluminium plates
• Fast, with impressive edge quality for most uses
• Great for irregular or freeform shapes

Considerations:

• Leaves a slightly wider cut width compared to laser cutting
• May require additional edge finishing

Ideal for:

• Industrial fabrication
• Automotive repairs
• Structural frameworks
• Any job involving substantial aluminium profiles

Waterjet cutting

Waterjet cutting harnesses the raw force of high pressure water mixed with abrasive particles to slice through aluminium. This technique is prized for its ability to handle both very thin foils and extremely thick plates, all while keeping the metal cool.

Advantages:

• No heat distortion or structural weakening
• Ultra-precision makes it suitable for intricate designs or small batch work
• Cuts a wide range of thicknesses and alloys

Considerations:

• Can be more expensive due to equipment and abrasive costs
• Requires a skilled operator for the best results

Ideal for:

• Aerospace components
• Decorative screens
• Complex assemblies where material integrity is critical

Hand tools

For smaller projects, prototypes, or onsite adjustments, hand tools remain an important part of learning how to cut aluminium sheet. They require minimal setup and can be surprisingly effective when used correctly.

• Hacksaw: Best for straight cuts in thin aluminium sheets or bars
• Tin snips: Best for cutting curves or intricate shapes in thin aluminium
• Utility knife: Best for scoring and snapping very thin aluminium, especially for ductwork or foil

Power tools

When you need more muscle, power tools are the answer for efficient, repeatable cuts (especially in medium to thick aluminium sheets). You should always wear goggles, gloves, and a dust mask when cutting aluminium.

• Circular Saw: Best for long, straight cuts in thicker aluminium sheet or plate
• Jigsaw: Best for curved or intricate cuts in aluminium
• Band Saw: Best for both straight and curved cuts, especially in thicker stock

Alternative sheet metal fabrication services

Here at Salamander Fabrications, we understand that there’s more to working with aluminium than just cutting. Sometimes, a project needs bending, welding, or other fabrication processes to bring your vision to life. Here’s a quick overview of other essential metalworking techniques.

Welding

Welding services are at the heart of most metal fabrication projects, especially for joining aluminium parts together. Whether you’re building frames, enclosures, or bespoke pieces, welding creates robust, long lasting joints.

Different types of welding:

• MIG Welding: Great for thicker aluminium, providing fast, strong welds
• Robotic MIG Welding: Delivers consistent quality and is ideal for high volume or repetitive work
• TIG Welding: Perfect for thin sheet aluminium or work that demands a clean, attractive finish
• Spot Welding: Used to join thin sheets without filler, common in automotive and appliance manufacturing

Want to know more? Read our detailed blog post on the subject – What Are The Different Types of Welding?

Sheet metal folding

Sheet metal folding is vital for producing parts with bends or angles, and CNC-controlled folding machines ensure every bend is precise and repeatable.

Stand-out features:

• Precision: Allows for exact bends and identical pieces that meet strict quality standards
• Cost-effective: Lowers costs by reducing the need for welding or additional assembly

Coating and finishing

Aluminium’s natural oxide layer makes it resistant to corrosion, but the right finishing or powder coating process can enhance durability and appearance even further.

Popular finishing techniques:

• Powder coating: Creates a tough, colourful finish that resists scratching and UV fading.
• Electroplating: Adds a decorative or protective metal layer which is ideal for high wear or visible components.
• Polishing and brushing: Delivers a high shine or a modern, textured look for decorative aluminium.

Choosing the best method for how to cut aluminium

Selecting the best method for how to cut aluminium depends on your tools, the thickness and alloy of the sheet, and the demands of your project. Hand tools are great for light work, while power tools and advanced machinery offer the accuracy and speed required for larger or more complex jobs.

Don’t forget to clean, deburr, and finish all cut edges for safety and appearance. If in doubt, consult a professional sheet metal contractor. Working with aluminium is as much about experience as it is about equipment.

Contact Salamander Fabrications for more information on our laser cutter – our method for how to cut aluminium

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us any time. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer and share our expertise.

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.