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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.
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Practical Guides for Your Next Job

Start with the question closest to the job you are doing.
Three separate square tubes showing opening geometry for a telescoping aluminum tubing fit review
Illustrative photo of square hollow aluminum tubes, sample tray.
Cleaner Cuts
October 1, 2026

Telescoping Aluminum Tubing: 5 Critical Fit Checks

Telescoping aluminum tubing needs a defined pair of tubes, not just two neighboring catalogue sizes. Review the receiving opening, inserted outside dimensions, supplied finish and required sliding span. Then identify the sample pair and the agreed fit check before releasing production.A positive calculated gap is useful screening information. It does not prove smooth movement, an…
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Four aluminum T-slot profile samples with different internal openings
Illustrative photo of T-slot industrial extrusions, overhead bench arrangement.
Cleaner Cuts
October 1, 2026

EN 755 vs EN 12020: 4 Critical Profile Checks

For an EN 755 vs EN 12020 comparison, specify the relevant part and edition before discussing profile tolerances. EN 755-9 addresses extruded profiles for general engineering applications. EN 12020-2 addresses precision profiles in EN AW-6060 and EN AW-6063 within its defined scope.Neither a shortened standard name nor the word “precision” supplies a complete cutting brief.…
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Window-frame profile cutaways with hollow chambers and a glass panel
Illustrative photo of aluminum window and door frames, key application section.
Cutting Basics
October 1, 2026

6060 vs 6063 Aluminum: 4 Essential Selection Checks

A 6060 vs 6063 aluminum comparison starts with the application, then the complete material condition. Both names appear in extrusion sourcing, but a shared profile shape does not make them interchangeable. Compare the specified temper, property requirements, visible finish and delivered documentation before approving a change.For a cutting project, keep the approved alloy designation attached…
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Three open U-shaped aluminum channel sections of different sizes rest side by side with their ends visible.
Illustrative photo of U-channel aluminum sections, cross-section view.
Cutting Basics
October 1, 2026

Aluminum Extrusion Tongue Ratio: 4 Essential Checks

Aluminum extrusion tongue ratio helps the extrusion supplier review a narrow opening and the die feature needed to form its adjoining space. Identify the relevant void area and gap or supporting-base width on the actual section. Keep the supplier's definition with the calculation. A profile can look simple in a thumbnail while a narrow opening…
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Multiple layers of hollow aluminum profiles rest on a steel rack with white foam strips around the sides and between some layers.
Illustrative photo of protected part handling, batch overview.
Cleaner Cuts
October 1, 2026

Aluminum Water Stains: 5 Essential Receiving Checks

Aluminum water stains need a clear receiving record and a supplier review of the actual material condition. Check the package, visible metal, moisture exposure, storage transition and affected quantity. Do not assume a dry-looking outside wrapper proves that every packed surface is dry. For cut-part and extrusion buyers, the immediate purchasing question is whether the…
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Five solid round aluminum bars of different diameters lie side by side with their end faces visible.
Illustrative photo of solid aluminum bars, cross-section view.
Cutting Basics
October 1, 2026

6061 vs 7075 Aluminum: 5 Essential Buying Checks

6061 vs 7075 aluminum is a material-specification decision before it is a cutting question. Compare the required alloy and temper, supplied product, fabrication route, finish and material evidence. A higher typical strength value does not authorize a substitution in an existing drawing. For cut blanks and machined components, keep the original requirement visible while asking…
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Get Your Cutting Details Ready

Use these simple files to collect the details you already know. Unknown items can wait for the discussion.

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Cutting List Template

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

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