Can You Cut Aluminum With A Miter Saw: Step-To-Step Guideline

When working with wood, a miter saw is a must-have tool. But what about when you’re working with metal? Can you use a miter saw to cut aluminum? The answer is yes – but there are a few things you need to keep in mind.

In this post, we’ll look at how to cut aluminum with a miter saw and share some tips for getting the best results. So if you’re looking to add aluminum to your list of materials that can be cut with a miter saw, read on!

Can You Cut Aluminum with a Miter Saw?

A miter saw is commonly used for making extremely precise cuts in wood. It features a blade that protrudes from the housing and can be rotated around to create different cut angles. While a miter saw is often used for cutting wood, it can also be used for cutting other materials, including aluminum.

To cut aluminum with a miter saw, you’ll need to use a non-ferrous metal cutting blade. These blades are specifically designed to cut metal, and they won’t create the same level of sparks and heat that you would get when using a regular wood-cutting blade. When choosing a non-ferrous metal cutting blade, select one designed to be used with your specific miter saw model.

Select the Right Blade

The first step is to select the right blade. A standard wood-cutting blade will not work for aluminum, as it will quickly become dull and not make a clean cut. Instead, you’ll need a carbide-tipped blade designed specifically for cutting aluminum. 

These blades are available at most hardware stores. Be sure to select a blade with a high tooth count; this will help to ensure a smooth, clean cut. In general, blades with more teeth produce cleaner cuts but may be more expensive. As always, read the manufacturer’s instructions carefully before making your purchase.

So Which Blades Do You Need to Cut Aluminum?

Circular Blades	Such blades work best while working with tilting angles to cut aluminum in the desired shapes
Razor Blades	The best if you want high-precision cuts with the metal
Sharp Cut Blades	Used to make sharp cuts to the metal to make it the perfectly cut metal piece
Coarse and very coarse cut blades	Lend some abrasive cutting to aluminum so that the finishing is fine

Mount the Blades

Once you’ve selected the right blade, it’s time to mount it onto your miter saw. Start by making sure that the saw is unplugged. Then, remove the old wood-cutting blade from the housing and replace it with the new aluminum-cutting blade. Be sure to tighten the blade securely in place; if it’s not mounted correctly, it could come loose and cause serious injury. Consult your miter saw’s manual for specific instructions on changing the blade.

Set Up Your Work Area

Next, you’ll need to set up your work area. Clear away any clutter, and ensure you have a flat, level surface to work on. Setting up a workbench or saw horses is a good idea if you’re working outdoors. You’ll also need to ensure you have enough light; cutting aluminum can be difficult if you can’t see what you’re doing. If possible, work near a window or in an area with good artificial lighting.

Clamp the Aluminum in Place

Once your work area is set up, it’s time to clamp the aluminum. You’ll need to use a vise or clamps to hold the aluminum securely while cutting it. If you’re using a vise, position the aluminum so it won’t slip out while you’re working. It’s also a good idea to position the vise so that it’s at a comfortable height for you to work on.

Mark the Aluminum

Before you start cutting, you’ll need to mark the aluminum. Use a tape measure and a pencil to mark the cut line on the aluminum. If possible, it’s a good idea to use a metal-cutting saw blade; these blades are designed specifically for cutting aluminum and other metals.

Cut the Aluminum with the Miter Saw

Once you’ve marked the aluminum, it’s time to start cutting. Slowly and carefully guide the blade through the metal, following your cut line. If possible, try to keep the blade moving at a constant speed; this will help to prevent it from overheating and becoming damaged. 

After you’ve cut, remove the aluminum from the saw and clamp. Check the cut to make sure that it’s straight and clean-looking. If necessary, use a file or sandpaper to smooth out any rough edges.

How to Cut Aluminum with a Miter Saw

Cutting Aluminum Angles Using a Miter Saw 

You can make a few different types of miter cuts on aluminum angles. The most common type is the 45-degree cut, which joins two pieces of aluminum at a 90-degree angle. To make this cut, you’ll need to set your miter saw to 45 degrees. You can also make a bevel cut, similar to a miter cut but at an angle other than 90 degrees. 

For example, you might use an angle cut to create decorative trim for a door or window. To make a bevel cut, you’ll need to set your miter saw to the desired angle. 

Finally, you can make a compound cut, combining a miter cut and a bevel cut. This type of cut is often used when framing windows or doors. To make a compound cut, you’ll need to set your miter saw to the desired miter angle and bevel angle.

Type of Miter Saw to Use to Cut Aluminium

When it comes to cutting aluminum, a few different types of miter saws can be used. The Makita LS 1040 is an excellent option for those who need to make precision cuts. It has a laser guide that helps to ensure that each cut is straight and accurate. 

The Makita LS 1018 is another good choice for cutting aluminum. It has a smaller blade than the LS 1040, making it ideal for tight cuts in small spaces. 

The DeWALT D28730 is a good option for those who need to make large, deep cuts. It has a powerful motor that can handle heavy-duty cutting jobs.

All these saws have blades made from high-quality steel, which helps reduce friction and heat build-up when cutting through aluminum. In addition, these saws come with carbide-tipped blades designed to stay sharp for extended periods. 

Finally, each of these saws has a dust collection system that helps to keep your work area clean and free of debris. When choosing a miter saw for aluminum, the Makita LS 1040, Makita LS 1018, and DeWALT D28730 are all excellent choices.

Which Blades Do You Need to Cut Aluminum? 

One of the most common questions is, “which blades do I need to cut aluminum?” It’s a great question with a few different answers, depending on the thickness of the material you’re cutting. Here’s a quick breakdown: 

• For material up to 1/8-inch thick, use a blade with ten teeth per inch, such as a 10-inch x 100-tooth or 12-inch x 120-tooth blade. 
• Use eight teeth per inch when cutting material that is as thin as ¼ inch thick.
• Try using a blade with only six teeth per diameter inch for thicker aluminum sheets 

In general, you’ll want to use a blade with fewer teeth for thicker materials and more for thinner materials. This is because fewer teeth mean less friction and heat buildup, which can be an issue when cutting aluminum. 

Another important factor to consider is the type of saw you’re using. 

Using a table or radial arm saw, you’ll want to use an AI/ATB (alternating top bevel) style blade. However, if you’re using a miter saw, you’ll want to use an ATB (alternating top bevel) style blade. This is because AI/ATB blades are designed for use with sliding miter saws and will damage the blade on a non-sliding miter saw.

Alternate Ways to Cut Aluminium

One method that can be used to cut aluminum is plasma cutting. This involves using a high-powered plasma torch to cut through the metal. While this method can be very effective, it is also very dangerous and should only be attempted by experienced professionals.

Water jet cutting may be the best option if you’re looking for a more precise method of cutting aluminum. This involves using a high-pressure stream of water to cut through the metal. Water jet cutting is extremely accurate and can be used to create complex shapes and patterns. However, it is also very expensive and requires specialized equipment.

Finally, laser cutting is another option that can be used to cut aluminum. Laser Cutters use a focused beam of light to cut through the metal. This method is extremely precise and can produce clean, precise cuts. However, it is also very expensive and requires specialized equipment.

Tips for Cutting Aluminum Safely 

If you’re working with aluminum, there are a few things you need to keep in mind to stay safe. Here are some tips for cutting aluminum safely:

• Wear the proper safety gear. This includes gloves, goggles, and a respirator.
• Use the right tools. A hacksaw or jigsaw is best for cutting aluminum.
• Use a lubricant. This will help to prevent the aluminum from overheating and make the cut more difficult.
• Make sure the area is well-ventilated. Aluminum dust can be dangerous if inhaled, so it’s important to have good ventilation when cutting it.

FAQ

Conclusion

Miter saws are a great tool for cutting aluminum, but you need to be careful to use the right blade and take precautions against fire sparks. However, you can safely and easily cut aluminum with these types of saws with little care.