Working with aluminum can be tricky. It's a soft metal, and if you don't use the right saw, you'll end up with a jagged mess or a blade that's dull before you finish the job. I learned this the hard way when I tried to cut some aluminum trim for my garage with a regular wood-cutting blade. Big mistake! After ruining the trim and nearly stripping the teeth off my saw, I decided to do some research. Turns out, there are specific saws and blades designed for aluminum, and they make a world of difference. So, if you're planning an aluminum project, save yourself the headache and start with the right tool.
Product Overview
- DEWALT 20V MAX Circular Saw: Cordless convenience with a high-speed motor for fast, clean cuts.
- Evolution Power Tools RAGE5-S Multi-Purpose Cutting Chop Saw: Versatile chop saw that cuts steel, aluminum, wood, and plastic with one blade.
- Milwaukee 6370-20 Metal Cutting Circular Saw: Powerful saw designed specifically for metal cutting, including aluminum.
- Makita XSH06PT 18V LXT Brushless 7-1/4" Circular Saw Kit: Cordless circular saw with a brushless motor for extended run time and power.
- SKILSAW SPT70WM-22 15-Amp 7-1/4-Inch Aluminum Circular Saw: A corded option designed specifically for cutting aluminum.
Top 5 Best Saws for Cutting Aluminum
1. DEWALT 20V MAX Circular Saw
This cordless circular saw from DEWALT offers excellent portability and cutting power for aluminum. It features a high-speed motor that delivers fast, smooth cuts, and the lightweight design makes it easy to handle. It's a great option for both professionals and DIYers tackling various aluminum projects.
Pros:
- ✅ Cordless design offers freedom of movement.
- ✅ High-speed motor for efficient cutting.
- ✅ Lightweight and easy to handle.
Cons:
- ❌ Battery and charger are sold separately.
- ❌ May require multiple passes for thicker aluminum.
- ❌ Blade included is not specifically for aluminum.
Verdict: A solid cordless choice for users who already own DEWALT 20V MAX batteries and need a versatile saw for various projects, including aluminum.
2. Evolution Power Tools RAGE5-S Multi-Purpose Cutting Chop Saw
The Evolution RAGE5-S is a versatile chop saw designed to cut through steel, aluminum, wood, and plastic using a single blade. This makes it a great option for anyone who needs a multi-purpose tool for a variety of projects. The clean cuts and powerful motor make it a popular choice.
Pros:
- ✅ Multi-material cutting capability with one blade.
- ✅ Clean and precise cuts.
- ✅ Powerful motor for demanding applications.
Cons:
- ❌ Can be a bit loud during operation.
- ❌ Some users report the included blade wears quickly.
- ❌ Larger footprint than a circular saw.
Verdict: Ideal for those who need a chop saw that can handle a wide range of materials without needing to change blades frequently.
3. Milwaukee 6370-20 Metal Cutting Circular Saw
This Milwaukee circular saw is specifically designed for metal cutting, and it excels at cutting aluminum. It features a powerful motor and a durable construction that can withstand the rigors of metalworking. If you frequently work with aluminum, this saw is a great investment.
Pros:
- ✅ Specifically designed for metal cutting, including aluminum.
- ✅ Powerful motor for demanding applications.
- ✅ Durable construction for long-lasting performance.
Cons:
- ❌ Corded design limits portability.
- ❌ More expensive than some other options.
- ❌ Primarily for metal, less versatile for other materials.
Verdict: Best for professionals and serious DIYers who primarily work with metal and need a dedicated, high-performance saw.
4. Makita XSH06PT 18V LXT Brushless 7-1/4" Circular Saw Kit
This Makita cordless circular saw kit provides excellent cutting performance and extended run time thanks to its brushless motor. It's a great option for aluminum cutting, especially when paired with a blade designed for non-ferrous metals. The kit includes two batteries, making it a convenient choice for all-day use.
Pros:
- ✅ Brushless motor for extended run time and power.
- ✅ Cordless design for portability.
- ✅ Includes two batteries for continuous use.
Cons:
- ❌ Can be expensive compared to corded options.
- ❌ Blade included is not specifically for aluminum.
- ❌ May require slower feed rate for thicker aluminum.
Verdict: An excellent cordless option for those who want the convenience of battery power and the performance of a brushless motor. Great if you already have other Makita 18V tools.
5. SKILSAW SPT70WM-22 15-Amp 7-1/4-Inch Aluminum Circular Saw
The SKILSAW SPT70WM-22 is a corded circular saw specifically designed for cutting aluminum. Its high-powered motor and specialized blade make quick work of aluminum sheets and extrusions. The saw's lightweight design also makes it easy to maneuver.
Pros:
- ✅ Specifically designed for cutting aluminum.
- ✅ Powerful 15-amp motor.
- ✅ Lightweight design for easy handling.
Cons:
- ❌ Corded design limits portability.
- ❌ Primarily for aluminum, less versatile for other materials.
- ❌ Some users find the dust collection inadequate.
Verdict: A great corded option for those who primarily cut aluminum and want a saw specifically designed for the task.
Buying Guide
Choosing the right saw for cutting aluminum depends on several factors, including the type of projects you'll be working on, your budget, and whether you prefer corded or cordless power. Here are some key considerations to keep in mind:
- Blade Type: This is the most important factor. Use a blade specifically designed for cutting non-ferrous metals like aluminum. These blades typically have a high tooth count and a special grind that prevents the aluminum from grabbing and causing kickback. Carbide-tipped blades are a good choice for their durability.
- Saw Type: Circular saws, chop saws, and even jigsaws can be used for cutting aluminum, depending on the application. Circular saws are versatile for general cutting, chop saws are ideal for making precise miter cuts, and jigsaws are useful for cutting curves and intricate shapes.
- Power Source: Corded saws offer consistent power and are a good choice for heavy-duty applications. Cordless saws provide greater portability and convenience, but you'll need to ensure you have enough battery power to complete your project.
- Safety Features: Look for saws with features like electric brakes, blade guards, and dust collection ports to help keep you safe and your work area clean.
- Motor Power: A more powerful motor will make it easier to cut through thicker aluminum and prevent the saw from bogging down.
- Material Thickness: Consider the thickness of the aluminum you'll be cutting. Thicker materials require more powerful saws and blades with a higher tooth count.
- Your Skill Level: If you're a beginner, start with a simpler saw that's easy to control. As you gain experience, you can upgrade to more advanced models with more features.
FAQs
Q: Can I use a regular wood-cutting blade to cut aluminum?
A: While it's possible, it's not recommended. Wood-cutting blades are designed for softer materials and can grab the aluminum, causing kickback and a rough cut. It can also damage the blade.
Q: What safety precautions should I take when cutting aluminum?
A: Always wear safety glasses to protect your eyes from flying debris. Use a dust mask to avoid inhaling aluminum dust. Secure the aluminum workpiece to prevent it from moving during cutting. And, of course, never remove any safety guards from the saw.
Q: How can I prevent aluminum from sticking to the blade?
A: Use a lubricant like cutting oil or wax to reduce friction and prevent the aluminum from sticking to the blade. Apply the lubricant to the blade before each cut.
Q: What is the best type of blade for cutting aluminum?
A: Carbide-tipped blades with a high tooth count (60 or more) are generally considered the best for cutting aluminum. These blades provide clean cuts and are durable enough to withstand the wear and tear of metal cutting.
Q: Should I choose a corded or cordless saw for cutting aluminum?
A: It depends on your needs. Corded saws offer consistent power and are ideal for heavy-duty applications. Cordless saws provide greater portability and convenience, but you'll need to ensure you have enough battery power to complete your project.
Conclusion
Choosing the best saw for cutting aluminum really comes down to your specific needs and the types of projects you'll be tackling. If you need portability, a cordless option like the DEWALT or Makita is a great choice. For dedicated metal cutting, the Milwaukee is a powerhouse. And if you want a versatile saw that can handle multiple materials, the Evolution RAGE5-S is a solid pick. Ultimately, the right saw will make your aluminum projects easier, safer, and more enjoyable. Make sure to always use the correct blade!
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