Cutting wood on a table saw is routine. Cutting metal on one? That’s a whole different story — and one that demands a cautious, well-informed approach. While it’s possible to cut certain types of metal on a table saw, you can’t just slap on any blade and hope for the best. It’s about matching the right blade to the right material and using proper technique.
Done correctly, cutting aluminum or non-ferrous metals on a table saw can be clean and surprisingly fast. Done wrong, you’ll ruin your blade, damage your saw, or worse — put yourself at risk. Let’s walk through the best setups, blades, and practices for cutting metal safely and effectively on a table saw.
Can You Cut Metal on a Table Saw?
The short answer: yes, but only certain types. Table saws can cut soft, non-ferrous metals like aluminum, brass, and copper. They should not be used to cut steel or hardened metals — that’s what metal chop saws or abrasive saws are for.
Stick to this rule of thumb:
- Aluminum: YES — With the right blade and feed rate
- Brass and Copper: YES — Slow and steady wins here
- Steel, Iron, Stainless: NO — Too hard, too dangerous
Best Blades for Cutting Metal on a Table Saw
Using the wrong blade is asking for trouble. You’ll want a carbide-tipped blade made specifically for non-ferrous metals. These blades have a negative hook angle to prevent grabbing and kicking, plus high tooth counts to reduce chipping.
1. Freud LU89M010 10-Inch Non-Ferrous Metal Blade
- 80-tooth, carbide-tipped
- Negative hook angle for safety
- Ideal for aluminum sheets, extrusions, and profiles
Price: ~$85
2. Diablo D1080N Non-Ferrous 10-Inch Saw Blade
- 80-tooth with thin kerf
- Laser-cut stabilizer vents for heat control
- Works well with miter saws too
Price: ~$70
3. Tenryu Alumi-Cut Series Blade
- Premium Japanese blade
- 90-tooth, ultra-smooth finish
- Lasts longer than standard carbide blades
Price: ~$120
Important Tips for Cutting Metal on a Table Saw
- Use Clamps: Keep your metal piece locked down. Vibration is your enemy.
- Set Slow Feed Rate: Let the blade do the work. Forcing it will overheat the blade and cause chatter.
- Use Wax Lubricant: Rub a metal-cutting wax like Boelube on the blade or workpiece. It reduces heat and prolongs blade life.
- Collect the Chips: Aluminum chips fly fast. Use a magnetic tray or shop vac positioned nearby (but away from the blade path).
- Wear Eye and Ear Protection: Cutting metal is LOUD and throws tiny fragments. Face shield is better than glasses here.
Can You Use a Standard Wood Blade?
No — and you shouldn’t try. Wood blades are designed to eject chips fast and aggressively. Cutting metal requires slow, controlled chip removal and a completely different tooth geometry. Using a wood blade on aluminum can lead to kickback, broken teeth, and dangerous binding.
Better Alternatives for Heavy-Duty Metal Cutting
If you plan to cut metal regularly or need to work with steel, there are better tools for the job:
- DeWalt D28715 14″ Chop Saw — Abrasive wheel cutter, good for mild steel
- Evolution RAGE2 14-Inch Multi-Purpose Cutting Saw — Cold-cut saw for steel, aluminum, and wood
- Milwaukee 6370-21 Metal Cutting Circular Saw — Perfect for steel plate and heavy tubing
Final Thoughts
Cutting aluminum and other non-ferrous metals on a table saw is completely doable — but it’s not something you can improvise. The right blade, a smart feed rate, and a steady setup make all the difference. If you’re working with thin stock or need precise, clean edges on aluminum extrusions or sheet goods, a properly equipped table saw can absolutely handle the task.
But for steel, cast iron, or regular metal fabrication? Leave that to the saws built for it. Know your limits, pick the right blade, and treat metal cutting like a separate skillset — because it is.