Aluminum Cutting Guides & Practical Tips

Choosing a machine? Dealing with rough edges or wasted material? Find a practical guide below, then ask us about your own cutting job.

Practical Guides for Your Next Job

Start with the question closest to the job you are doing.
Two aluminum profile end faces beside an inspection probe
Illustrative photo of thin-wall edge review, end-face comparison.
October 1, 2026

Aluminum Burr Height: 4 Critical Inspection Checks

Aluminum burr height is a defined edge measurement, not a judgment that a cut looks smooth. To make it useful for acceptance, identify the edge, the reference surface, the dimension being evaluated and the permitted result. Agree a measurement method that can inspect the specified region on the actual part.A height result and a burr's…
Two hollow aluminum extrusion members meeting at a mitered corner on a workshop table.
Illustrative photo of machine frame corner parts, partial frame context.
October 1, 2026

Aluminum Butt vs Miter Joints: 4 Critical Decisions

Aluminum butt vs miter joints change the corner geometry, cut-length references and connector requirements of a frame. In this comparison, a butt corner uses a square-ended member meeting the side of another member. A miter corner uses angled ends meeting at the corner. Choose the joint together with its approved hardware and assembled dimensions.Neither shape…
Probe beside the edge of a machined open aluminum enclosure
Illustrative photo of thin-wall edge review, inspection area detail.
October 1, 2026

Aluminum Blind Tapped Holes: 5 Critical Drawing Checks

Aluminum blind tapped holes need separate definitions for the required thread and the space available beneath it. State the complete thread designation, required usable threaded length, hole-depth requirement and finished condition. Confirm the mating fastener and an inspection method that checks the actual requirement.A blind hole does not pass through the part. Its internal geometry…
Probe beside the corner of a machined open enclosure
Illustrative photo of thin-wall edge review, inspection bench top view.
October 1, 2026

Aluminum Powder Coating Masking: A Clear 3-Step Plan

Aluminum powder coating masking defines which surfaces must remain free of powder coating and where each coating boundary belongs. A useful order names those surfaces on the drawing, agrees the masking scope with the finisher and checks a representative finished part against the approved requirements.“Mask the holes” leaves too much open to interpretation. A threaded…
Digital caliper beside a machined block with a large bore and smaller holes
Illustrative photo of sample evaluation bench, inspection context.
October 1, 2026

Aluminum Thread Galling: 4 Critical Assembly Checks

Aluminum thread galling involves adhesion between contacting thread surfaces and can lead to seizure or damage during assembly. When a joint binds unexpectedly, stop treating it as a normal tightening step. Identify the mating parts and approved assembly condition, preserve the evidence and ask the responsible technical team to establish the cause.A tight screw alone…
Circular blade on a dark foam pad beside a pen and notebook
Circular saw blade arranged for a tooling review. AI-generated illustration.
October 1, 2026

Aluminum Saw Blade Bore: 4 Critical Order Checks

Confirm an aluminum saw blade bore against the approved mounting specification for the exact machine before ordering. Keep the center-hole dimension, additional mounting features, any approved reduction ring and complete blade product number together. A blade that appears to slide onto a shaft has not completed the compatibility review.This guide focuses on the center-hole decision…

Get Your Cutting Details Ready

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CSV · Editable template

Cutting List Template

List the finished lengths, quantities, angles and drawing references for your job.

Download the Cut-List File

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