Cutting Aluminum With a Circular Saw – Everything You Need to Know

| Last Updated: March 31, 2021

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Circular saws are versatile tools as they can cut almost any material, so long as you have the correct blade.

In the article below, we'll explain how to correctly cut Aluminum using your circular saw

TL;DR (Too Long, Didn't Read)

Follow these instructions, and you'll be on track for successfully cutting Aluminum using a circular saw. 

  • You'll need a diamond-tipped continuous-rim blade 
  • You'll need a steady supply of coolant to combat overheating
  • It's important to wear protective equipment when cutting Aluminum

How To Cut Aluminum With a Circular Saw

In the section below, we'll explain a few tips on how to correctly and safely cut Aluminum. 

Diamond Tipped Continuous-Rim Blades Are Built To Cut Aluminum

You'll find many websites telling you to go for a blade that has a high number of teeth, around 120; while this isn't wrong, there are better options to go with. 

Firstly, you'll want a blade that can cut through non-ferrous metals, which Aluminum is; this would be the job for a diamond-tipped blade. The diamond adds an extra protection layer to cut through abrasive, rough materials; this includes brick, concrete, and metals like Aluminum, brass, and copper. 

We also believe that it'd be better for you to pair this with a continuous-rim blade; the benefits of a continuous rim are significant. If you're looking for a clean, smooth cut through your Aluminum, this is your go-to blade. 

The reason it provides such a smooth cut is that it's one single sharp blade, rather than multiple blades with tight gullets; the lack of teeth means there's no shock being caused to the material, reducing any risk of chipping by a large margin. You'll also want to look out for a blade with a hard bond as they're known for durability and longevity. 

Coolant Significantly Reduces Heat Caused By Friction

You can go down a few avenues with what coolant and system to use. There are machines designed to attach to your saw that'll supply a steady stream of coolant liquid, or you can periodically stop and cool the material and blade down using water. 

You could also prepare the material and saw prior to cutting by lathering WD-40 over it. However, this will take constant application as it dries out quickly. 

Another option is to use wax sticks; applying these directly to the teeth will reduce the chance of kickback and overheating. Wax sticks also last far longer than WD-40 and won't need constant reapplication. 

Protective Equipment Is Necessary, Especially When Working With Metal

Just like any machine, protective equipment is needed to operate it safely. However, when working with metal, it cannot be stressed enough how important it is. We'd recommend you get yourself a full face covering mask to limit any risk of shrapnel/chipping injuring your face. 

Protective eyewear is also required to protect your eyes for the same reason; when working with metals like Aluminum, your risk of injuring yourself from chipping/shrapnel increases. The last thing you want to damage is your eyesight. 

Earplugs should also be prioritized as they save you from any long-lasting hearing issues that come with machines emitting 80 decibels or more. To provide further protection from kickback, you should have the Aluminum held down using two or more clamps; this helps maintain accuracy and safety from it moving around during cutting. 


Just like with any material, there will be a blade specialized in cutting through it. It's always important to know which blade will suit as well as knowing accessories or tips to improve the overall cutting quality. 

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