How to Cut Aluminum with Table Saw – A Comprehensive Guide

In this article, we’ll talk about How to Cut Aluminum with Table saw with proper Step by Step Instructions. The most extraordinary table saw is built with the intention of cutting wood in mind, but that doesn’t mean it has to stop there. It can cut Plexiglass, PVC piping, Styrofoam, and cardboard in addition to all varieties of wood. What about more lasting materials, such as metals?

The question is, can a table saw be cut aluminum? Yes. A table saw can cut aluminum, but it is not suitable for skinny aluminum sheet metal and is not the safest saw to use due to the risk of backlash.

Cutting aluminum is more difficult than cutting other materials. It is a serious safety risk, and some precautions must be taken to perform the cut safely and effectively. This article will teach you how to cut aluminum with a table saw and how to cut metal using safer and more effective methods.

How to Use a Table Saw for Cutting Aluminum:

It is advised that you follow particular measures while cutting aluminum using a table saw. The measures outlined below reduce the likelihood of an accident occurring while working on a project and improve the quality of your part. When you’re ready to get started, follow this step-by-step guide.

Step-by-Step Process of How to Cut Aluminum with Table Saw:

  • First, unplug the table saw.
  • Carefully remove the blade you normally use to cut wood.
  • Replace the blade with a non-ferrous material blade. If your table saw has a smaller blade slot, use a 7 7-14-inch blade.
  • Use beeswax or paraffin wax to lubricate the blade.
  • You can wax the surface to make the metal glide smoothly across it.
  • If feasible, adjust the arbor’s speed. The suggested speed ranges from 750 to 1500 FPM.
  • Put on eye and facial protection, as well as ear plugs and work gloves.
  • Reconnect the saw.
  • Place the aluminum piece on the table saw. Stay away from the kickback zone. With one exception, use the saw as you would for wood, but move the metal carefully into the blade.
  • When you’re finished cutting, turn off the table saw.
  • A regular file, deburring tool, or Scotch-Brite pad can be used to smooth or straighten out rough edges.

Supplies Needed:

  • Ear Plugs
  • Work Gloves
  • Eye and face protection
  • Blade for Non-Ferrous Material
  • Push tool
  • Metal File, Deburring Tool, or Scotch-Brite Pad

Blade Selection:

The blade you require will be determined by the thickness of the material. A typical non-ferrous blade will work great on most aluminum in most circumstances, but as you approach thinner dimensions, you should reduce the number of teeth on your blade. This table shows how many teeth per inch of blade diameter are required to cut through various aluminum thicknesses.

Teeth per Inch of Diameter Needed for Aluminum of Different Thicknesses:

Thickness of AluminumTeeth per Inch of Diameter
⅛ Inch10
⅛-¼ Inch8
Thicker than ¼ Inch6

If the aluminum is less than ⅛ of an inch thick, you should not use your table saw to cut it.


The usage of cutting oil is another crucial aspect while cutting metal. The greatest danger is that the saw will grab and fracture the material. This allows the blade to rapidly fling huge bits of shattered metal or the entire portion.

Lubricate the blade with low-viscosity cutting lubricant to keep it from becoming clogged with filth or clinging to the aluminum itself. I use WD-40 for this. Not only does the lubricant lessen the chance of splintering, but it also keeps the blade and aluminum cool, minimizing overheating.

In addition to lubricating to prevent kickback, it is advised that the aluminum workpiece be tightly clamped before cutting. If the blade does bite into the aluminum, then the chance that the part will fly away is a lot smaller.

Gauge and Thickness of Aluminum Sheet Metal:

Furthermore, if you are cutting bigger pieces of aluminum, make sure that your motor is powerful enough to handle the thickness. If your table saw can’t cut through large chunks of hardwood like butter, it won’t cut through metal either.

Precautions To Take When Cutting Aluminum On A Table Saw:

Because safety comes first, there are a few things you should check before you begin. These precautions ensure that you can securely cut metal with a table saw.

1- Wear the Necessary Safety Equipment:

Accidents happen in a single second, so arming yourself ahead of time with safety glasses or, better still, a face shield is a good idea. Wear apparel that will shield your arms from flying scorching flakes. Earplugs help shield your ears from the loud noises made during the cutting process.

2- Pushing Instruments:

It’s becoming easier to keep your hands away from the blade. Use a push stick, as seen in this YouTube video, or a hold-down stick, such as this one.

A push stick allows you to move the part ahead while keeping your hands at a safe distance and maintaining control over the aluminum’s stability. To cut smaller parts, I always use my crosscut sled.

3- Choose the Appropriate Blade:

It is vital that the blade match the strength of aluminum. If you don’t utilize the proper blade, the blade will most likely break or bend. More information is available above. Follow the table to find the exact number of teeth on the blade so that you can make flawless cuts securely.

4- Dust Removal:

If the table saw is designed to cut wood, remember to turn off the dust collection system. Because heated aluminum bits can start a fire in the container.

Lubrication is required because aluminum has a tendency to heat up and flake. To avoid this and to cut smoothly, lubricate it thoroughly before beginning and add oil on a regular basis. More on this can be found earlier in this post.

What Saw Will Cut Through Aluminum?

Since aluminum is so lightweight, high-speed sawing is optimal. One of the most popular ways to cut this metal alloy efficiently is to use a circular saw blade.

Can Aluminum be Cut with a Wood Blade?

A blade purpose-made to cut aluminum might work fine in a lot of cases for wood, but don’t expect that it’ll cut everything you might throw at it as neatly as it cuts aluminum just because it’s made to cut metal.

How do you Cut Thick Aluminum?

Use a wood-cutting saw with carbide-tipped blades to cut most aluminum.

Do you need a Special Blade to Cut Aluminum?

You’ll need different blades for different kinds of metal. You should be able to use a carbide-tipped abrasive cutoff wheel for non-ferrous metals like brass, aluminum, copper, or lead.

Can I Cut Aluminium with a Steel Blade?

Ferrous metal blades can be used for cutting all types of metal construction products including steel siding, roofing, steel studs, and other construction steel. 

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