Aluminum is lightweight, corrosion-resistant, and conductive to heat and electricity. These qualities make aluminum a dream to machine if you have the right tools—but if you don’t, it can be a pain. With that said, here are the best tools available for machining aluminum that respect and adapt to its qualities.

Cold or miter saws

When working with aluminum, using the right type of saw is crucial. A miter saw is the most popular choice, as it allows for clean, angled cuts. A cold saw, on the other hand, is known for producing burr-free edges and offers the advantage of slower cutting speeds and cooler operations. This is particularly useful for aluminum, as its low melting point makes it difficult to machine when it overheats. Cold saws get the job done quickly without overheating the metal.

Regardless of the saw you choose, make sure you choose the right saw blade tooth count. Additionally, remember that there are saw blades created specifically for cutting aluminum, so it’s worthwhile checking those out.

A milling machine with appropriate end mill flutes

A milling machine equipped with the right end mill flutes is vital for achieving smooth finishes and precise dimensions when machining aluminum. Specialized end mills, such as those with high helix angles and double flutes, are better at removing chips and improving efficiency. This is important for aluminum because it can clog drills that don’t work quickly enough or funnel away chips properly.

Additionally, using the appropriate speed and feed rates can significantly reduce wear on tools and improve the overall quality of the machined components.

Metal shears

Metal shears can execute straight cuts and intricate designs while ensuring minimal deformation of aluminum. Investing in high-quality metal shears designed for aluminum allows for quicker and cleaner cuts, boosting quality and productivity.

A high-quality cutting fluid

Lastly, you can’t machine aluminum without a high-quality cutting fluid. As we’ve mentioned, aluminum is a soft metal prone to melting and clogging if it overheats. Cutting fluids reduce friction and dissipate heat, thereby mitigating these problems. As with saw blades, there are cutting fluids formulated specifically for aluminum to produce the best results possible.

The best tools available for machining aluminum include a cold or miter saw, an appropriately outfitted milling machine, metal shears, and a high-quality cutting fluid. These tools cater to aluminum’s unique qualities to help you make durable, accurate products.