Router Cutting Tips for Aluminium: Getting the Best Results

Mastering Aluminium Routing with the Right Tools

Routing aluminium requires precision, the right technique, and most importantly, quality bits designed specifically for metal cutting. At Atlas Tools, our aluminium router bits are engineered to deliver clean cuts, extended tool life, and professional results every time.

Why Bit Quality Matters

Not all router bits are created equal, especially when working with aluminium. Our aluminium bits feature several advanced technologies that set them apart:

• Polished Flutes – Smooth, polished flutes reduce chip buildup and improve material evacuation, resulting in cleaner cuts and less heat generation
• Passivation Treatment – Enhanced surface treatment increases corrosion resistance and overall durability, extending the life of your bits
• DLC Coating Option – Diamond-Like Carbon coating provides exceptional hardness, reduced friction, and significantly longer tool life

Essential Cutting Tips

1. Speed and Feed Rates

Use higher spindle speeds (18,000-24,000 RPM) with moderate feed rates. Aluminium cuts best with fast rotation and steady, controlled movement. Too slow, and you'll generate excessive heat; too fast, and you risk chipping.

2. Lubrication is Key

Always use a suitable cutting lubricant or coolant. This reduces heat buildup, prevents material welding to the bit, and extends tool life. Even our DLC-coated bits benefit from proper lubrication.

3. Chip Evacuation

The polished flutes on our bits are designed for optimal chip clearance, but you still need to clear chips regularly. Use compressed air or a vacuum system to keep the cutting area clean and prevent re-cutting.

4. Climb vs. Conventional Cutting

For aluminium, climb cutting (where the bit rotates in the same direction as the feed) typically produces better edge quality and reduces burring. However, ensure your router table or CNC has minimal backlash.

5. Depth of Cut

Take multiple shallow passes rather than one deep cut. For most applications, 1-3mm depth per pass is ideal. This reduces tool stress and heat generation while improving cut quality.

6. Secure Your Workpiece

Aluminium can be slippery. Use proper clamping or vacuum hold-down systems to prevent movement during cutting, which can damage both your workpiece and the bit.

Maintenance for Longevity

Even with passivation treatment and DLC coating, proper maintenance extends bit life:

• Clean bits after each use with a suitable solvent to remove aluminium residue
• Inspect cutting edges regularly for wear or damage
• Store bits in a dry environment to prevent corrosion
• Avoid dropping or striking bits against hard surfaces

The Atlas Tools Advantage

Our aluminium router bits combine precision engineering with advanced surface treatments to deliver professional results. Whether you choose our standard passivation-treated bits or upgrade to DLC coating for maximum performance, you're investing in tools designed for the demands of metal routing.

Ready to achieve cleaner cuts and longer tool life? Explore our range of aluminium router bits and experience the difference quality makes.