How to Cut Aluminium

Choosing aluminium rather than timber for your building project has many benefits – but one you may not have considered is that it is extremely flexible when it comes to size.  Although aluminium cladding, battens and other profiles may come in specific lengths (for example, most DecoWood profiles are usually 6.5 metres long), this does not mean you are restricted in what size your project can be. Aluminium is lightweight and thin (although still durable), and can be easily cut down into any length you desire, in order to perfectly suit the needs of your unique project.  You can cut your aluminium building profiles either onsite or before you arrive.  

If you have not thought about cutting your own aluminium, you should, as it will benefit both you and your project – and it’s as simple as cutting regular timber. 

No Sparks, No Hassle

Although cutting many metals can result in sparks flying, causing concerns about fire safety or burns, this is not an issue with aluminium. Aluminium is a non-ferrous metal, meaning it does not contain iron, and therefore does not spark when cut. 

Make the most of your building materials

Don’t waste even a centimetre of your aluminium. Cutting aluminium yourself is highly economical, as it means you can use the leftover pieces elsewhere on your project and get the most out of every length. You can even add these extra pieces to the end of an existing length to create a longer profile.  Cutting your own aluminium will also save you the cost of having another builder or metalworker do it for you, making it an economical option. 

What you will need 

If you are concerned that cutting aluminium will require a host of technical equipment, you needn’t be. To cut aluminium profiles, all you will need is:

  • •A mitre or drop saw, jigsaw or table
  • •A non-ferrous, soft metal aluminium cutting blade with a carbide tip for your saw
  • •A measuring tape
  • •A clamp
  • •Safety equipment including safety glasses, gloves and hearing protection 

We also recommend you wear long sleeves, as cutting aluminium can causes pieces of swarf and grit to go flying, and these can become embedded in the skin.  

What to do

Cutting aluminium is not rocket science. All you need to do is follow a few simple steps:

  • •Choose your saw and blade
  • •Measure your desired length
  • •Angle your blade
  • •Position the length of aluminium
  • •Check your safety equipment
How to Cut DecoWood Cheat Sheet

DecoWood not only has the appearance of timber, it can also be cut as easily as timber boards. Being aluminium, DecoWood profiles can be easily downsized so they suit the specific size requirements of your building project. 

To cut your aluminium DecoWood profiles down to size like a professional, download our new How to Cut DecoWood Cheat Sheet

It contains detailed, step-by-step instructions which will help you choose the right blade for your project, angle your saw correctly, position your DecoWood so it does not move, and achieve a neat, clean cut. 



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