Whether you are a passionate DIYer or use your circular saw in a professional setting, you’re likely to deal with aluminum a lot. From bike frames to construction, the material is ubiquitous.
However, the task might seem intimidating unless you have the best circular saw blade for cutting aluminum out there as an average one might fail to cut it (pun intended).
Here you’ll find comprehensive reviews of the top five products for this purpose. For those who want their decision to be informed, there’s a buyer’s guide included. Go ahead and find out what tool you need for an effortless cutting experience!
5 Best Circular Saw Blade for Cutting Aluminum Reviewed
- DeWALT DW9152 Circular Saw Blade – My Top Pick
- Oshlun SBNF-072560 Aluminum Cutting Blade – Runner up
- Diablo D1080N Blade – Premium Pick
- TOMAX TMA71460
- IRWIN 4935560
Here are my impressions of the five products that best answer the question how to cut aluminum with a circular saw. While most users will be happy with the Top Pick, feel free to explore other options depending on your situation.
1. DeWALT Circular Saw Blade for Aluminum: Top Pick
Made by the globally famous US-based power tool manufacturer DeWALT, this moderately priced blade combines solid material with impressive cutting speed.
It is a 6 1/2 inch blade with 36 teeth, which corresponds to about six teeth per inch of diameter. This might sound unimpressive compared to other numbers; however, the serration works well with thick and relatively thin aluminum pieces alike. It is especially useful for bulkier stock. Those looking for extra smooth and clean cuts on the thin stock might want a blade that comes with more teeth.
For most users, the limitation is made up for by how quickly the blade cuts through aluminum. This is an ultra-thin kerf model, meaning improved cutting speed due to less resistance and reduced material loss. One likely concern is that a blade made with such a delicate kerf might turn out wobbly, but this is not the case with DeWALT DW9152.
It is very accurate, with no sign of increased vibration. An anti-stick rim is included to minimize unwanted friction, which also adds to cutting efficiency.
This blade offers superior strength and durability due to carbide teeth. This means it will withstand temperature fluctuations more readily than most popular blade materials and isn’t prone to corrosion.
The only major flaw I’ve been able to find with this otherwise excellent product is that it tends to spray fragments around when used in a cordless saw, so it’s best to wear eye protection in this case. Another aspect in which the blade stands out is that a year’s full warranty applies as opposed to the usual limited, offering extended coverage.
- Great value for money;
- Versatile because it combines precision and heavy-duty features;
- Strong, non-corrosive carbide material;
- Fast cutting;
- Great for rough cuts when processing thicker aluminum pieces.
Could be better:
- Not the biggest tooth count available
- Sprays chips and shavings in cordless saws
2. Oshlun Precise Blade to Cut Aluminum: Runner-Up
This blade model is made of tungsten carbide classified as C1. This is the lowest carbide grade, which generally means it is the softest and has its pros and cons. While it may sound like an indication of poor performance, don’t let the number fool you — lower grade carbide tools are less likely to chip or break on contact with metal. Not only does the tooth material last long, but it reduces burrs.
The carbide tips of the triple chip grade or TCG teeth used in this blade were designed with maximum precision in mind. This pairs well with an increased number of teeth per unit of diameter as compared to the top pick, namely 60T per 7 ¼ inches.
This feature makes it an appropriate tool for settings where clean cuts are a priority, especially with thin stock. A negative angle is another characteristic that maximizes operator control.
Unfortunately, the TCG configuration also reduces the feed rate. This Oshlun blade is inferior to our absolute favorite in terms of cutting speed, which appears to be a more common priority than utter precision.
The model comes with heat vents for cooler operation, potentially increasing its longevity. It’s just a little pricier than DeWALT’s No. 1, but it does deliver in settings where accuracy is key. It also doesn’t have the spraying problem as much as the top pick.
Oshlun’s warranty covers only factory defects and doesn’t apply to normal wear and tear, which is the most common scenario with blade manufacturers.
- Durable C1 tips;
- Precision-friendly tooth design and material;
- Tooth count will work with nearly any aluminum thickness;
- Cooling vents;
- Relatively low fragment spraying.
Could be better:
- Relatively slow;
3. Diablo Pro-Level Circular Saw Blade for Aluminum: Premium Pick
The main disadvantage of the model is obvious the moment you look at its price tag; however, it boasts quite a number of features to compensate for it.
Made of titanium cobalt carbide of high density, the blade is designed specifically for non-ferrous metals and plastic. It is a corrosion-resistant material enhanced with shock-resistant brazing to protect it in extreme situations such as impact.
Apart from fighting corrosion, the Perm-Shield coating reduces gum-up, sticking, and unwanted heat to a minimum. The later effect is added to by heat vents.
This model uses TCG teeth to prevent burring. With 80 teeth over a diameter of 10 inches, it offers a healthy balance of speed and precision. A laser-cut 0.094 inch thin kerf increases the feed of material, further improving control and accuracy, and the vibration is kept in check by special stabilizer vents.
These also reduce noise, making it a comfortable and safe blade to work with. The company offers its general limited lifelong warranty to cover any defects in this tool.
- Extremely long-lasting, shock-resistant carbide material;
- Reduced noise;
- Vibration control for improved precision;
- TCG design minimized burring;
- Reasonably fast at 80T/10 inches.
Could be better:
4. TOMAX Circular Saw: Cutting Aluminum on a Budget
Made by a fully integrated company with over 10 years of experience in the industry, this blade offers good performance without hitting your budget too hard.
With a diameter of 7 ¼ inches, the carbide anti-corrosive blade comes with 60 teeth. The triple chip grade technology is used to prevent it from leaving burrs on the surface and promotes clean cuts in a wide range of aluminum applications. It is also designed to cut plastic.
Cutting speed is reasonably high with this model. It comes with laser-cut slots that generally reduce vibration and sideways movement, adding to precision while also extending its lifespan.
However, it can go off-balance on some occasions, producing increased vibration instead. It also generates a lot of fragments, so eye protection is highly recommended. TOMAX offers a lifelong limited warranty for its blade.
- Clean cuts;
- Versatile in terms of stock material and thickness;
- Good cutting speed.
Could be better:
- Eye protection is a must;
- Occasional vibration problems.
5. IRWIN Blade for Cutting Aluminum: Ensured Safety
Made by a US-based brand of Stanley Black & Decker, this premium blade clearly prioritizes safety. This includes an anti-kickback design that reduces dust production and sparks, meaning the risk it poses to the user’s eyes and health overall is minimized (which is not to say it doesn’t produce occasional fragments or require appropriate protection).
The blade has 68 teeth per diameter of 7 ¼ inches, making it perfect for cutting thin aluminum. The serration pattern produces extremely clean cuts, which effect is further increased by anti-vibration vents.
Made of carbide, the product lasts reasonably long; also, it’s not the most wear-resistant model out there. A limited warranty is applied.
- Very precise;
- Great for thin material;
- Reduced kickback;
- Moderately long-lasting.
Could be better:
Best Circular Saw Blades for Cutting Aluminum: Buyer’s Guide
Even experienced DIYers and professionals need a set of rules to guide their decision when shopping. Here’s how you choose an aluminum cutting blade for your circular saw that you won’t regret buying.
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Types of circular saw blades for cutting aluminum
You need a blade that states it can be used to cut non-ferrous metals or, specifically, aluminum. While most will be designated as metal cutting blades, some fall into the category of abrasive ones, cutting through 11+ gauge stock at the cost of material loss.
This article deals primarily with aluminum cutting blades. These come in different diameters, materials, tooth shapes and counts, hook angles, and kerfs.
This is usually stated on the label in inches/centimeters and depends on the saw that you are using. The size of your blade determines the depth cut and how quickly it works. It’s also essential that the size of the arbor, i.e., blade mounting hole, matches that of the saw.
Generally, greater tooth counts give cleaner cuts, but you should rely on teeth per unit of diameter rather than the number as such. Those working with thick pieces of aluminum might prefer lower tooth counts as it increases speed.
Tooth shape and arrangement
TCG, or triple chip grade, is a common geometry in blades for non-ferrous metals. Low, flat teeth alternate with taller ones that come with chamfered corners. The arrangement helps prevent chipping of the surface.
Aluminum cutting blades come with carbide tips, often with a protective coating. The material is valued for its long life and resistance to corrosion as well as impact.
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Hook angle refers to where and how much each tooth leans. Aluminum generally requires zero or, preferably, negative hook angle, maximizing control, and precision.
Kerf is a term that describes the thickness of the blade. As a rule of thumb, thinner kerfs are preferable for aluminum as they are faster and more precise.
Extras & Safety
Some aluminum cutting blades for circular saws come with vents to reduce heat, vibration, and/or noise, which is a good way to improve user comfort, safety, and control. Take into account that some blades will produce a spatter of shavings.
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Best Circular Saw Blades for Cutting Aluminum FAQ
In this section, I answer some of the most popular questions that arise when people go shopping for aluminum-friendly blades to use on their circular saws.
Can I cut aluminum with a circular saw?
While miter saws are considered to be the preferred tool to use with aluminum, it is still possible to cut it with a circular one. It is essential that the right blade and procedure are applied in this case.
Can you cut aluminum with a carbide saw blade?
Absolutely. Carbide is one of the toughest materials found in circular saw blades and will work perfectly well, provided that the blade’s overall design was made with a view for aluminum cutting.
How do you cut aluminum soffit with a circular saw?
The general aluminum cutting procedure is applied, and so do the safety rules. Eye and hearing protection, as well as gloves, are a must. Since aluminum soffits tend to get brittle in cold weather, it’s often recommended that you flip your blade backward for greater cutting precision. Fine-toothed blades are preferable. Don’t hurry as you move the saw but make the cut slowly.
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Aluminum Cutting Blades: Bottomline
If you are looking for a blade to cut aluminum using your circular saw, don’t hesitate to choose a specialized non-ferrous metal cutting one like the models featured in my reviews.
I recommend DeWALT DW9152 as the most versatile option for medium to thick stock that comes at a moderate price and offers great cutting efficiency. However, those whose priorities are extreme precision with thin sheets or shoppers looking for a premium tool might choose another model. A lot depends on the application and, of course, the budget.
What do you need an aluminum cutting blade for? Please write in the comments section, and don’t forget to share your experience with this type of accessories, if any.