How To Properly Cut Aluminium Sheets and Plates

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Aluminium sheets and plates are used in a wide range of industries, from aerospace to construction. They are versatile, lightweight, and durable, making them a popular choice for many applications. However, cutting aluminium sheets and plates can be challenging, as they require precision and the right tools. 

Whether you’re working on a DIY project or a professional metalworking job, knowing how to cut aluminium sheets and plates properly is essential for achieving precise and accurate results. 

In this blog, we’ll cover everything you need to know about how to properly cut aluminium sheets and plates.

Tools for Cutting Aluminium Sheets and Plates

There are several tools you can use to cut aluminium sheets and plates. Let’s take a look at some of the most effective options:

    1. Metal Shears: These specialised scissors-like tools are ideal for cutting aluminium sheets and plates up to about 1/8 inch thick. They work by applying a shearing force that cuts through the metal cleanly and quickly.
    2. Circular Saw: A circular saw equipped with a carbide-tipped blade can be an effective tool for cutting thick aluminium sheets and plates. Make sure to use a blade specifically designed for cutting metal.
    3. Jigsaw: A jigsaw with a metal-cutting blade is a versatile tool that can be used for cutting curves and intricate shapes in aluminium sheets and plates. It is particularly useful for projects that require a high level of precision.
    4. Metal Brake: A metal brake is a tool that can be used to bend aluminium sheets and plates to the desired angle or shape. This is useful for creating flanges or forming metal into a specific shape.
    5. Hacksaw: A hacksaw with a metal-cutting blade can be used for cutting thin aluminium sheets and plates. However, it is a slow and laborious process that may not be suitable for larger projects.
    6. CNC Laser Cut Machine: If you’re looking for precision and efficiency, a CNC laser cut machine is the way to go. It uses a powerful laser beam to cut through aluminium sheets and plates with incredible accuracy and speed. Phillips India offers high-quality EFC CNC Laser Cutting Machine, TFC CNC Laser Cutting Machine and BFC CNC Laser Cutting Machine.
    7. CNC Router: This machine is ideal for cutting aluminum sheets and plates with complex shapes and designs. It uses a rotating cutting tool to cut through the material with precision and accuracy.
    8. CNC Milling Machine: This machine uses a rotating cutting tool to cut aluminum sheets and plates into complex shapes and designs, creating the desired shape. CNC milling machines can produce high-quality cuts with tight tolerances, making them ideal for precision machining applications.
    9. CNC Turret Punch Press: This machine is ideal for cutting aluminum sheets into a variety of shapes, including holes, slots, and other features, by punching through the aluminum sheet. It provides high-quality cuts quickly and efficiently for high-volume production applications.
    10. CNC Waterjet Cutting Machine: This machine uses a high-pressure stream of water to cut through aluminum. It is ideal for cutting thicker sheets and plates and can produce clean, precise cuts with no heat distortion.
    11. CNC Plasma Cutting Machine: This machine uses plasma to cut through aluminum. It is ideal for cutting thicker sheets and plates and can produce clean, accurate cuts.

Cutting Tips and Tricks

Once you have selected the appropriate tool for cutting aluminium sheets and plates, there are a few tips and tricks to keep in mind:

    1. Use Lubricant: Applying a lubricant, such as WD-40, to the blade or cutting area can help reduce friction and prevent the aluminium from sticking to the blade. This makes the cutting process smoother and helps prevent the blade from overheating.
    2. Smaller Diameter Blades are Better: When using a circular saw or jigsaw, a smaller diameter blade is better for cutting aluminium sheets and plates as it will create less friction and generate less heat, resulting in a cleaner and smoother cut.
    3. Clamp, Clamp, Clamp: When cutting aluminium sheets and plates, it is essential to secure the material firmly in place using clamps or a vise. This helps prevent the material from moving or shifting during the cutting process, which can result in uneven cuts or damaged blades.


Cutting aluminium sheets and plates can be challenging, but with the right tools and techniques, it is possible to achieve precise and accurate results. Whether you’re using metal shears, a circular saw, a jigsaw, a metal brake, a hacksaw, or a CNC laser cut machine, it is essential to follow proper safety procedures and take the time to select the appropriate tool for the job. 

By keeping these tips and tricks in mind, you can ensure that your aluminium cutting projects are a success.

If you’re looking for high-quality CNC metal cutting services, look no further than Phillips Corporation India. Our advanced CNC-based machines, such as CNC laser sheet metal cutting machines, can handle even the most complex metal forming projects with ease. 

Contact us today to learn more about our services and how we can help you achieve your metalworking goals.


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