Cutting Aluminum on Table Saws: A Helpful Guide

Table saws are generally used for cutting wood, but woodworkers don’t just work with this material alone.

It is fairly common for pros to cut other materials other than wood with their table saws.

That includes softer materials, such as styrofoam, cardboard, plastic, that will provide less resistance to your table saw.

Cutting those would be a breeze, but you may wonder if cutting aluminum on table saws or other metals, for that matter, is possible.

Some have used their table saw in cutting metals in the past and were successful.

With that in mind, let’s discuss how to cut aluminum with table saws and other related topics.

Can You Cut Aluminum With a Table Saw?

The short answer to this is yes, it is possible; in fact, it could be considered a common way for craftsmen to use their table saw to cut aluminum.

Bear in mind, though, that aluminum comes in two general types: plate metal and sheet metal.

As much as possible, you have to settle with cutting aluminum plate metal because of its thickness.

Also, when cutting aluminum with table saws, using electric or bench shears is ideal if your metal is very thin.

However, if you want to push it to the limit, you should do the cutting with extreme care with protection for your eyes and skin.

You can use a table saw to cut aluminum sheets with up to a thickness of 0.1285 inches. Any more than that, you are putting yourself in harm’s way.

What will happen if you try to cut very thin aluminum sheets? For starters, the pieces of aluminum could come flying back to you.

Safety Measures

From amateurs to pros, there is no shame in following safety tips. Carelessness in the workplace, whatever your skill level, can lead to accidents, injuries, and severe cases, disabilities, and deaths.

Here are a few tips you should consider before cutting aluminum on table saws.

1. Always wear protective gear for your eyes, hands, skin, and hair, especially if you are new to using table saws. That includes gloves, goggles, and work clothes.
2. You must also never run your hand and fingers on freshly-cut aluminum.
3. Do not rush to cut aluminum with table saws, as it may affect the quality of the cut or worse; you may get injured.
4. Make sure to clamp the aluminum in place. If the blade grabs the metal during the cut, it may result in a damaged blade or fly and injure you in the process.

Can a Wood Saw Blade Cut Aluminum?

Ideally, you must have a saw blade meant for slicing non-ferrous materials such as bronze, brass, and aluminum.

You must also measure your aluminum’s thickness to confirm that your blade’s teeth count corresponds to it.

If uncertain about which particular wood saw blade fits the size of the aluminum you are cutting, it wouldn’t hurt to ask for professional advice.

Overall, cutting aluminum on table saws is a common practice for many.

It could also be a regular activity for you; just make sure you have all the tools.

What Are the Disadvantages of Using Table Saw To Cut Aluminum?

It is not surprising to know that using the table saw for cutting aluminum has some drawbacks.

Since this power tool is not specifically designed for cutting metals, below are a few reasons that may convince you to do the cutting another way.

Kickback

This scenario is possibly one of the worst hazards you may encounter when it comes to table saw operation.

Kickback is when the material you are cutting gets eaten by the saw blade and “kicks” back the material to the machine operator.

The risk of kickback is greater with aluminum, as this material is not designed to get cut by a table saw, to begin with.

Blade Swapping

It is not a big deal, but you may find it tedious to change the blades again when you return to cutting wood.

Otherwise, you'll end up with uneven or dirty cuts.

Metal Shavings

As many people have experienced, you may get many metal shavings all over the workplace. Some of it may get on your face.

Not only could this be annoying, but it can be a serious health hazard.

What Is the Best Way To Cut Aluminum?

Cutting aluminum with table saws is a legitimate option. Still, there are other ways you can get your metal cut.

Below are a couple of tools you may consider to cut aluminum better and safely.

Tin Snips

Before we jump right into the instructions, let’s check out the definition and common uses of tin snips.

Tin snips or shears is a classic hand tool specially designed to cut through metal sheets.

The appearance of the tin snips bears a strong resemblance to common scissors.

That said, the similarity ends there since the tin snips are sharper and stronger.

This hand tool excels in precise cutting, thanks to its extra-wide jaws and plier-like handle.

Its cutting power is attributed to the compound leverage that diminishes the effort needed for cutting.

Aside from aluminum, tin snips could also work on copper, gutters, studs, and metal roofing. 

Using Tin Snips To Cut Aluminum

To cut aluminum with tin snips, you must follow these steps:

1. Trace or draw the parts you will be cutting. Whether lines, circles, and other shapes, having a guide makes it easier to cut.
2. Then, use force on your tin snip handle to make the first cut.
3. Afterward, start cutting away. If you have tin snips designed to cut in one direction, use those accordingly.

Make sure that you wear protection for your hands and fingers. Tin snips and aluminum sheets are extremely sharp and could easily cause cuts.

Cold Chisel

Ahead of looking at instructions on using the cold chisel for cutting aluminum, let’s see its definition and general purpose.

A cold chisel is defined as a tool made from tempered steel and used for slicing cold metals.

Cold metals are those elements that are not exposed and soften by heat sources such as forges.

Types of Cold Chisels

The cold chisel has four types, namely:

• Flat Chisel: The most popular type, it is used for cutting rods and bars. You can also use it when tin snips cannot cut a sheet metal that is too thick or dense to cut.
• Round Nose Chisel: You use this for making cuts on semi-circular grooves.
• Diamond Point Chisel: This cold chisel is utilized for cleaning out difficult spots.
• Crosscut Chisel: This type is used for making slots and cutting grooves.

Using Cold Chisel To Cut Aluminum

Follow these steps when cutting aluminum with a cold chisel:

1. Prepare your cold chisel by sharpening it to around 60/70 degrees. Make sure the chisel is wider than the aluminum sheet you’re cutting.
2. Get a honing guide and fit your chisel into it. A honing guide is a tool that locks your cold chisel from above and below or from the sides.
3. After that, set the guide at the right angle. Then, place the edge of your chisel on the opposite of a cross-cut file.
4. Hold the honing guide with your hands. Afterward, move the chisel back and forth.
5. Switch to medium grit once scratches are evident on the chisel’s bevel. Switch to fine grit when you notice new scratches.
6. The bevel should be constantly clean and dry between each grit switching.
7. Next, put the aluminum sheet into a vice and secure it. 
8. Then, start using a ball-peen hammer to start pounding the chisel’s handle.
9. Continue with hitting the handle until a notch is visible.
10. Try snapping your aluminum piece into two with your bare hands.
11. If it didn’t work, place it on the vice again and start using a hack saw to continue cutting it.  

Table Saw

As a staple in every woodworker’s workshop, the table saw is viewed by many as arguably the most important tool to carpentry.

There are six most common types of table saw: the contractor, jobsite, compact, cabinet, benchtop, cabinet, and hybrid.

These types are divided into two primary categories: stationary (cabinet, contractor, and hybrid) and portable (jobsite, compact, and benchtop).

Using Table Saw To Cut Aluminum

The steps for cutting an aluminum material with a table saw are:

1. Make sure your table saw is unplugged, and the blade equipped to your machine can cut non-ferrous materials.
2. Grease your saw blade with paraffin wax or beeswax. There should also be an amount of wax on the table top to help the aluminum slide with ease.
3. Once the table saw is plugged, start feeding the aluminum into the blade slowly. Be certain that you are not in the kickback zone.

Recommended arbor speed is from 750 to 1500 FPM.

Cutting Aluminum on Table Saws: The Conclusion

While the tin snips and cold chisel method are effective and safe ways to cut aluminum, they cannot beat the table saw method when it comes to speed and accuracy.

Considering you made the efforts to follow the safety measure, it wouldn’t make sense to prefer other methods when you have a table saw at your disposal.

Out of the three methods presented, only the table saw method produces the best results with the quickest time.