Cutting aluminum effectively with a circular saw requires more than just a standard wood blade. If you’ve ever tried, you know it can result in messy edges, dangerous kickbacks, or even ruin your material. That’s why choosing the best circular saw blade for aluminum is crucial for achieving clean, precise cuts and ensuring your safety. Aluminum is a soft, non-ferrous metal, and it needs a specialized blade designed to handle its unique properties, preventing gumming up and providing a smooth finish. We’ve put together a list of top-performing blades that excel at slicing through aluminum, making your projects much easier and more professional.
Quick Product Comparison
Our Top 5 Best Circular Saw Blade For Aluminum Reviews – Expert Tested & Recommended
1. Benchmark Abrasives Tungsten Carbide 7-1/4 Inch Circular Saw Blade for Aluminum and Non-Ferrous Metal, 80 Teeth
If you’re serious about cutting aluminum and other non-ferrous metals, the Benchmark Abrasives Tungsten Carbide blade is an excellent choice. It’s specifically designed to give you a clean, smooth cut, minimizing burrs and preventing the metal from gumming up the blade. This blade is engineered for durability and precision, making it a reliable tool for various projects.
Key Features That Stand Out
- ✓ 80 Tungsten Carbide Teeth for superior durability and a super clean cut on aluminum.
- ✓ Versatile design suitable for aluminum, brass, copper, and plastics, expanding its utility.
- ✓ Industrial-grade TCT construction ensures long-lasting performance and reliability.
- ✓ Optimized geometry for miter saws and circular saws, delivering seamless cutting.
Why We Recommend It
We recommend this blade because it consistently delivers on its promise for clean, precise cuts on non-ferrous metals. The tungsten carbide tips are incredibly resilient, ensuring a long blade life even with frequent use. It’s an ideal blade for both professionals and serious DIYers who need dependable performance when working with aluminum.
Best For
This blade is best for users who frequently cut aluminum extrusions, sheets, brass, or copper tubing, especially when looking for industrial-grade precision and durability.
Pros and Cons
Pros:
- Cuts aluminum cleanly and precisely without burrs.
- Highly durable tungsten carbide tips for extended life.
- Versatile for a range of non-ferrous metals and plastics.
- Meets industrial standards for reliable performance.
Cons:
- Higher tooth count means it might cut slower than lower-tooth options.
- Primarily designed for non-ferrous metals, less suitable for wood or steel.
Customer Reviews
Customer Review: “Easily and cleanly cuts 10 series 80-20 aluminum extrusions using a small compound miter saw. Only about 14 cuts so far, I’ll later note if it doesn’t hold up, but so far so good.”
Customer Review: “Easily and cleanly cuts 10 series 80-20 aluminum extrusions using a small compound miter saw. Only about 14 cuts so far, I’ll later note if it doesn’t hold up, but so far so good.Read more”
2. KENDO Carbide-Tipped 10 Inch Circular Saw Blade Set for Woodworking Miter and Table Saws
While marketed for woodworking, the KENDO Carbide-Tipped 10 Inch Circular Saw Blade Set offers a versatile solution that can also handle certain non-ferrous metals like aluminum with its high tooth count options. This set comes with both a 40T and a 60T blade, providing flexibility for different cutting tasks and material thicknesses. Its robust construction ensures durability and precise results.
Key Features That Stand Out
- ✓ Set includes 40T and 60T carbide-tipped blades, offering versatility for different materials.
- ✓ Tough carbide construction delivers enhanced accuracy and extended cutting life.
- ✓ ATB (Alternating Top Bevel) tooth design ensures clean cuts, reducing splintering.
- ✓ 10-inch diameter and 5/8 inch arbor size fit most standard miter and table saws.
Why We Recommend It
We selected the KENDO set as an Editor’s Choice because it provides excellent value and versatility. While primarily for wood, the 60T blade, with its carbide tips and ATB design, can perform surprisingly well on thinner aluminum profiles, delivering clean finishes. It’s a great all-around set for a workshop that handles both wood and occasional light aluminum work.
Best For
This blade set is best for DIY enthusiasts and woodworkers who need versatile blades for various projects, including precise cuts on wood, MDF, plastics, and occasional light-gauge aluminum or non-ferrous metals.
Pros and Cons
Pros:
- Excellent value with two blades for different applications.
- Carbide-tipped for extended durability and sharpness.
- ATB tooth design provides very clean cuts.
- Suitable for a wide range of materials, including thin aluminum.
Cons:
- Lower tooth count (40T) might not be ideal for very fine aluminum finishes.
- Primarily designed for wood, so optimal aluminum performance might require a slower feed rate.
Customer Reviews
Customer Review: “I recently purchased the KENDO 2-Pack 10 Inch Carbide-Tipped Circular Saw Blades (40T & 60T), and I’m really impressed with their performance! These blades are perfect for both woodworkers and DIY enthusiasts looking to achieve clean, precise cuts. The 40-tooth blade is fantastic for general cutting.”
Customer Review: “OK, I will admit it: I bought these blades because they are inexpensive and I had made some drawers that had 23 gauge pins in them that I had to cut down. Rather than take the chance ruining a good blade, I figured worst case I will ruin a $10 blade. I put the 60 tooth version in my table saw and I.”
3. FOXBC 7-1/4 Inch 140 Tooth Carbon Circular Saw Blade for Fine Finish Wood and Plastic
For those on a tighter budget, the FOXBC 7-1/4 Inch 140 Tooth Carbon Circular Saw Blade offers a surprisingly capable option, especially for very fine finishes. While explicitly designed for wood and plastic, its exceptionally high tooth count (140T) and fine kerf mean it can deliver incredibly smooth, splinter-free cuts on delicate materials. This precision makes it a contender for light-gauge or thin aluminum where a pristine edge is paramount.
Key Features That Stand Out
- ✓ Features an impressive 140 teeth for ultra-fine, smooth cuts.
- ✓ Designed with a thin 0.086″ kerf to minimize material waste and resistance.
- ✓ Ideal for achieving splinter-free edges on delicate materials like fine wood and plastic.
- ✓ Available in a convenient 3-pack, offering great value for multiple projects.
Why We Recommend It
We recommend the FOXBC blade as our best budget pick due to its outstanding ability to produce fine finishes. While it’s carbon steel, not carbide, its very high tooth count gives it the capacity to cut through thin aluminum or soft non-ferrous metals with minimal burring, assuming careful handling and a suitable lubricant. It’s a cost-effective solution for precision cuts when a dedicated carbide blade isn’t in the budget.
Best For
This blade is best for hobbyists or DIYers looking for an affordable option for ultra-fine finishing on wood, plastic, and very thin aluminum sheets where minimal splintering or burring is desired.
Pros and Cons
Pros:
- Extremely high tooth count for exceptionally smooth finishes.
- Thin kerf design reduces material loss and cutting effort.
- Great value, especially in a 3-pack.
- Effectively prevents splintering on delicate materials.
Cons:
- Carbon steel construction means less durability than carbide for harder metals.
- Not ideal for cutting thicker aluminum or more robust non-ferrous metals.
- Requires a slower feed rate and lubricant for best results on aluminum.
Customer Reviews
Customer Review: “I usually stick with established brands but took a chance and FoxBC impressed me. I used this blade to cut 15.75″ x 0.75″ thick plastic garage floor tiles—over 40 cuts—and it ripped straighter than expected with minimal burrs. My circular saw only stopped twice, likely due to tile shifting (F-clamps.”
Customer Review: “The blades are very sharp. Great value for the money.”
4. CRALY Carbide Tipped 7-1/4 Inch Circular Saw Blade for Aluminum and Non-Ferrous Metal, 56 Teeth
The CRALY Carbide Tipped 7-1/4 Inch Circular Saw Blade is a solid performer designed specifically for cutting aluminum and other non-ferrous metals. With its 56 TCG (Triple Chip Grind) teeth, it delivers a durable and clean cutting experience. The blade incorporates several features like a thin kerf and non-stick coating to ensure smooth operation and extended blade life, making it a valuable addition to any workshop.
Key Features That Stand Out
- ✓ Features 56 TCG (Triple Chip Grind) teeth for superior durability and clean cuts on metal.
- ✓ Ultra-fine grain carbide tips provide a super clean cutting surface and extreme service life.
- ✓ Thin kerf design (2.0 mm) reduces cutting resistance and minimizes material waste.
- ✓ Includes non-stick coating and laser-cut expansion slots for cooler, smoother operation.
Why We Recommend It
We recommend the CRALY blade for its well-rounded performance in cutting aluminum and non-ferrous metals. The combination of TCG teeth and high-quality carbide ensures both clean cuts and impressive longevity. It’s an efficient and reliable option that helps prevent material overheating and gumming, which are common issues when cutting softer metals.
Best For
This blade is best for users requiring a reliable, durable blade for general-purpose cutting of aluminum profiles, sheets, and other non-ferrous metals, offering a great balance of speed and finish.
Pros and Cons
Pros:
- Excellent durability and long lifespan due to carbide tips.
- TCG tooth geometry ensures very clean cuts.
- Thin kerf reduces load on the saw and improves efficiency.
- Non-stick coating prevents gumming and friction.
Cons:
- May be slightly more expensive than basic carbon steel blades.
- 56 teeth might not be as fine a finish as higher tooth count blades on very thin materials.
Customer Reviews
Customer Review: “I don’t do a lot of work with aluminum and didn’t want to commit a large sum of money to a more expensive household named brand that would simply sit on a rack for an extended period of time so I decided to give this CRALY a try. Did you know the name Craly has the root based in Anglo-Saxon culture.”
Customer Review: “Gets the job done on G10, micarta, and various acrylics with no chipping or burning.”
5. Diablo 7-1/4 Inch Circular Saw Blade, 56 TCG Teeth, Designed for Thick Aluminum Cutting
Diablo is a well-respected name in saw blades, and their 7-1/4 Inch Circular Saw Blade for thick aluminum cutting lives up to the reputation. Featuring 56 TCG (Triple Chip Grind) teeth and made with high-performance TiCo Super-Density Micro-Grain Carbide, this blade is engineered to provide extreme cutting longevity and superior durability. It’s specifically designed to handle the challenges of thicker aluminum, delivering clean, burr-free cuts.
Key Features That Stand Out
- ✓ Features 56 TCG (Triple Chip Grind) teeth for balanced speed, durability, and a clean finish.
- ✓ Constructed with TiCo Super-Density Micro-Grain Carbide for exceptional blade life.
- ✓ Tri-Metal Shock Resistant Brazing enhances durability and impact resistance for tough cuts.
- ✓ Specifically engineered for cutting thick aluminum and other challenging non-ferrous metals.
Why We Recommend It
The Diablo blade is a top recommendation for anyone tackling substantial aluminum projects. Its specialized design truly excels with thicker materials, providing clean cuts without the common issues of gumming or excessive heat. The advanced carbide formulation and robust brazing mean this blade will last through many demanding cuts, offering reliable performance every time.
Best For
This blade is best for professionals and serious DIYers who frequently work with thick aluminum plates, extrusions, or other demanding non-ferrous metal applications where durability and a clean finish are essential.
Pros and Cons
Pros:
- Exceptional durability and longevity, even with thick materials.
- Designed specifically for thick aluminum, yielding clean, burr-free cuts.
- Advanced carbide and brazing technology for superior strength.
- Maintains sharpness and efficiency over long periods of use.
Cons:
- Higher price point than many general-purpose blades.
- Might be overkill for very thin aluminum sheets or less frequent use.
Customer Reviews
Customer Review: “This blade was ideal, cut through plexiglass accurately. I wonder if they have another type to cut circle.”
Customer Review: “This blade (Diablo D1080N, 80T TCG) cuts beyond what I expected. 0.093 ABS sheet – perfect and no melting, splintery plywood crosscut – perfect, melamine – perfect. I have cut these same materials with several different Hi-ATB blades including a freshly sharpened Forrest combo with pretty good res.”
Complete Buying Guide for Best Circular Saw Blade For Aluminum
Essential Factors We Consider
When you’re searching for the best circular saw blade for aluminum, it’s easy to feel overwhelmed by the choices. But don’t worry, we’re here to help you understand what truly matters. We focus on several key aspects to ensure you get a blade that performs perfectly for your needs. First, the tooth count is vital; generally, more teeth (like 60-80 TCG) mean a smoother, cleaner cut on aluminum, reducing burrs and preventing the metal from grabbing. Next, the tooth geometry, such as Triple Chip Grind (TCG), is specifically designed for non-ferrous metals to sheer off material effectively and dissipate heat, which is critical for aluminum. The material of the blade teeth is also paramount – carbide-tipped blades are a must for durability and sharpness when cutting aluminum, as they withstand the abrasive nature of metal much better than steel. Lastly, consider features like a thin kerf to minimize material waste and blade resistance, along with anti-friction coatings or expansion slots that help keep the blade cool and prevent warping during intense cutting sessions. These elements combined ensure you’re investing in a blade that’s safe, efficient, and delivers professional-grade results every time.
Budget Planning
Investing in the best circular saw blade for aluminum doesn’t necessarily mean breaking the bank, but it’s important to understand where your money goes. Entry-level, budget-friendly blades (like some carbon steel high-tooth-count options) might be suitable for occasional, light-duty work or very thin aluminum. However, for consistent use or thicker aluminum, you’ll want to consider mid-range to premium carbide-tipped blades. These typically offer superior longevity, cleaner cuts, and enhanced safety features, which ultimately save you money by preventing material waste and frequent blade replacements. Think about how often you’ll be cutting aluminum and the type of projects you’ll undertake. For a one-off project, a budget option might suffice, but for regular use or professional results, a higher-quality blade is a wise investment that will pay off in performance and durability. Always balance the upfront cost with the blade’s expected lifespan and the quality of cut you need.
Final Thoughts
Choosing the right circular saw blade for aluminum can make a huge difference in your projects. It’s not just about getting the job done, but about doing it safely, efficiently, and with a clean, professional finish. Remember to prioritize blades with high tooth counts (ideally TCG geometry) and carbide tips for optimal performance. Always use proper safety gear, including eye protection and gloves, and consider using a lubricant to further extend blade life and improve cut quality. With the right blade, cutting aluminum can be a smooth and satisfying process, opening up a whole new world of possibilities for your DIY or professional endeavors. We hope this guide helps you confidently select a blade that will serve you well for years to come.
Frequently Asked Questions
Q: Can I use a regular wood blade to cut aluminum?
A: No, it’s highly recommended not to use a regular wood blade for cutting aluminum. Wood blades have fewer teeth and a different tooth geometry (typically ATB for wood) that can grab, clog, and cause dangerous kickbacks when cutting aluminum. This can damage your material, the blade, and even cause serious injury. Always opt for a specialized circular saw blade for aluminum or non-ferrous metals.
Q: What features should I look for in an aluminum-cutting blade?
A: Look for blades with a high tooth count (60-80+ teeth) and a Triple Chip Grind (TCG) tooth geometry. Carbide-tipped teeth are essential for durability and clean cuts. A thin kerf and anti-stick coating can also help reduce heat and friction, leading to smoother, safer cuts.
Q: Do I need to use lubricant when cutting aluminum?
A: While not always strictly necessary for every cut, using a cutting lubricant or wax is highly recommended when cutting aluminum. It helps cool the blade, prevents aluminum from melting and sticking to the teeth (gumming up), and extends the blade’s life, resulting in a cleaner and smoother cut.
Q: What safety precautions should I take when cutting aluminum with a circular saw?
A: Always wear appropriate personal protective equipment (PPE), including safety glasses or a face shield, hearing protection, and gloves. Ensure your material is securely clamped down to prevent movement. Use a slower, consistent feed rate, and make sure the blade is specifically designed for cutting non-ferrous metals like aluminum.
Q: What’s the ideal RPM for cutting aluminum?
A: Generally, a slower RPM is better for cutting aluminum and other non-ferrous metals compared to cutting wood. High speeds can cause the aluminum to melt and gum up the blade. If your circular saw has variable speed, experiment with lower settings. Always refer to the blade manufacturer’s recommendations for optimal RPM and feed rate.
Finding the best circular saw blade for aluminum truly transforms your metalworking experience. From the incredibly durable Benchmark Abrasives to the versatile KENDO set, and even the budget-friendly FOXBC for fine finishes, there’s a perfect blade out there for every project and budget. Remember, selecting a blade specifically designed for non-ferrous metals, with high tooth counts and carbide tips, is key to achieving smooth, safe, and professional results. Don’t let the wrong blade hold you back—upgrade your toolkit today and experience the difference a specialized aluminum cutting blade makes!
I’m Darrell Julian, the founder, lead writer, and hands-on welding enthusiast behind ArcWeldingPro.com. With more than 15 years of real-world welding experience, I created this platform to share what I’ve learned in the field, in the shop, and in the heat of the arc.
