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Use A Feeds and Speeds CalculatorLook, you’re going to approaching the limits of what your machine can do in all likelihood. Cutting aluminum on a CNC Router is not a cakewalk, so...Use CNC Router Bits For Cutting Aluminum (Carbide Endmills)CNC Routers use a variety of specialized cutters that should not be used with aluminum. Downcut Spirals, Compression Cutters, and the like have no...Use Smaller Diameter CuttersThe other way to bump up the rpms is to use smaller diameter cutters. Forget about 1/2″ endmills. Drop down to 1/4″ maximum and typically less. Bec...Be Paranoid About Clearing ChipsI can’t stress this enough, especially when the material has an affinity to bond with the cutter.Recutting chips breaks more cutters than most any...Watch Cut Depths and Slotting–They Make It Harder to Clear ChipsThe deeper you cut and the closer to a slot the cutter travels in, the harder it is to clear the chips out of the bottom of the hole. Make more pas...Don’T Slow Down The Feedrate Too much!If you go too slow on your feedrate, you run the risk of making your tool rub rather than cutting. This is a much bigger risk for CNC Router users...If Your Machine Can’T Feed Fast Enough, Use Fewer Flutes and Increase Cut WidthNormally, we use 3 or fewer flutes with aluminum anyway–just don’t try a four or more flute cutter in aluminum!The reason is that aluminum produces...Use A Horsepower Limit to Derate For RigidityOkay, you’ve mastered the other 9 tips, and things are going well, but you’re now running up against the rigidity limits of your machine. If you pl...CNC Router Aluminum Sheet Work Is Different Than CNC Routers Cutting Aluminum PlateThere’s a world of difference for a CNC Router cutting thin aluminum sheet vs a CNC Router cutting thicker aluminum plate. The thicker the material...

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These machines come in many configurations, ranging from small DIY desktop CNC aluminum routers to industrial equipment used in manufacturing plants. Below, we’ve found five great machines for cutting aluminum. Since industry-grade CNC routers begin in the tens of thousands, we’ve focused on desktop options that are generally less than $1,000.

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