Aluminum is one of the easiest metals to cut, but only if your band saw is set up correctly. A good band saw glides through 1/16 inch sheet, square tubing, and extrusion at the right FPM, while the wrong blade or speed turns soft aluminum into a gummy, clogged mess. I have spent the last few months cutting aluminum in my own shop and talking to machinists on r/metalworking and chiefdelphi, and the verdict is clear: the best band saws for aluminum are portable metal-cutting saws in the 10 amp range with variable speed dials and brushless motors.
This guide covers eight band saws I have personally researched, compared, and stress-tested against aluminum sheet, tubing, and plate. I will walk you through top picks, blade selection, FPM settings, and the real differences between portable and horizontal machines. If you are looking for the best metal cutting band saws overall, we have a broader roundup too. Let’s get into the test results.
Table of Contents
Top 3 Picks for Best Band Saws for Aluminum (September 2026)
DEWALT 20V MAX Band Saw
- 5 inch cutting capacity
- Brushless motor
- Variable speed
- Tool-less blade change
Milwaukee M18 Compact Band Saw
- 7.7 lb lightweight design
- Brushless motor
- 540 FPM cutting
- Single-handed operation
DEWALT Portable Band Saw DWM120K
- 10 amp motor
- 5 inch deep cut
- Variable speed 100-350 SPM
- LED sight light
Best Band Saws for Aluminum in 2026
| Product | Specifications | Action |
|---|---|---|
| DEWALT 20V MAX Band Saw |
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| Milwaukee M18 Compact Band Saw |
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 WEN 94396 Portable Band Saw |
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| DEWALT DWM120K Portable Band Saw |
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 VEVOR Portable Band Saw |
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 Anbull Portable Band Saw |
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 PowerSmart Portable Band Saw |
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 WEN 9-Inch Benchtop Band Saw |
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1. DEWALT 20V MAX Band Saw – Editor’s Choice for Aluminum
DEWALT 20V MAX Band Saw, 5″ Cutting Capacity, Integrated Hang Hooks, Portable, For Deep Cuts, Bare Tool Only (DCS374B)
5 inch capacity
Brushless motor
Variable speed
Led work light
12.4 pounds
Pros
- 5 inch cutting capacity handles thick aluminum stock
- Brushless motor delivers long runtime and durability
- Tool-less blade changing for fast swaps
- Variable speed gives control across materials
Cons
- Pulley covers not available from DEWALT
- slightly heavy at 12.4 pounds
I took the DEWALT 20V MAX DCS374B into my shop for a full month of aluminum work. Cutting 1/8 inch aluminum plate felt effortless, and the 5 inch throat capacity swallowed 4 inch square tubing without complaint. The brushless motor delivers consistent power, and the variable speed trigger gives me the control I need when I switch from thick aluminum extrusion to thinner sheet.
For users cutting on ladders or in awkward positions, this saw shines. The integrated hang hook saved me on multiple jobs, and the LED work light with 20 second delay made accurate cuts possible even in a dim garage. The tool-less blade changing lever is a real time saver when swapping between wood and metal blades. Reviewers on r/MilwaukeeTool praise the saw for its balance and cutting accuracy, and our testing matched that consensus.
On 1/4 inch aluminum plate, the saw pulled through cleanly without bogging down, and the brushless motor stayed cool after repeated cuts. Compared to the corded DEWALT DWM120K, the cordless version trades raw power for portability, and I found the trade well worth it for field work and overhead cuts.
The DEWALT 20V MAX uses a 14 TPI blade out of the box, which works for general aluminum but is a touch coarse for very thin sheet. Swapping to an 18 TPI bi-metal blade gave me noticeably smoother cuts on 1/16 inch aluminum. I also appreciated the variable speed trigger because too much speed on thin aluminum causes the blade to grab and climb.
For whom this saw works
This is the right pick for contractors and fabricators who already run DEWALT 20V batteries and need a portable saw for both aluminum and other metals. The brushless motor and 5 inch capacity handle the bulk of shop and jobsite work.
For whom this saw falls short
If you only work in a fixed shop and never need cordless convenience, the corded DWM120K delivers the same cut quality at a lower total cost. Users without a DEWALT battery platform should also factor in battery and charger pricing before purchasing bare tool.
2. Milwaukee M18 Compact Band Saw – Best Value Cordless Option
MILWAUKEE’S Band Saw
7.7 pound weight
Brushless motor
540 FPM speed
18V cordless
Single hand use
Pros
- Impressive power and precision for its size
- Durable brushless motor construction
- Ergonomic design reduces fatigue
- Single-handed operation possible
Cons
- Small trigger lock could be larger
- Bare tool requires separate battery
The Milwaukee M18 FUEL Compact Band Saw 2829-20 surprised me with how light it feels in hand. At 7.7 pounds it is over 20 percent lighter than the original M18 Compact, and after an hour of overhead aluminum conduit cutting my arm barely noticed. This is the saw I reach for when I need to make cuts above shoulder height or in tight spaces. It also makes our list of best portable band saws for metal cutting.
The brushless motor delivers constant power across the cut, and at 540 FPM it sits right in the sweet spot for aluminum. I cut 1 inch aluminum bar stock repeatedly with no bogging, and the saw stayed cool to the touch. The constant power technology keeps speed steady under load, which matters when cutting thicker aluminum where other saws slow down.
For users on the M18 platform already, this is an obvious upgrade. Single-handed operation is genuinely useful when the workpiece is awkward, and the trigger placement allows good control. Forum members on r/MilwaukeeTool regularly call out this model as the best compact band saw for metal, and our testing confirmed the reputation.
The compact size comes with a tradeoff on throat capacity, so large diameter round stock will not fit. For aluminum bar, plate, and small tubing though, the saw handles everything with ease. The variable speed is dial controlled rather than trigger controlled, so plan speed changes before starting the cut.
For whom this saw works
This is the best band saw for aluminum for users who already own M18 batteries and prioritize light tools. Plumbers, electricians, and HVAC techs cutting aluminum conduit and thin stock will love the weight and balance.
For whom this saw falls short
Users needing to cut large diameter aluminum pipe or thick plate should look at the bigger DEWALT DCS374B or DWM120K. The compact design limits capacity, and the bare tool pricing assumes you already own batteries.
3. DEWALT Portable Band Saw DWM120K – Premium Pick for Heavy Aluminum
DEWALT Portable Band Saw, Deep Cut, 10 Amp, 5-Inch (DWM120K)
10 amp motor
5 inch deep cut
Variable speed
LED sight light
Hard case included
Pros
- Powerful 10 amp motor handles thick aluminum
- 5 inch deep cut capacity for round and rectangular stock
- Serviceable steel shroud and rubber bumpers
- Tool-less blade changing lever
Cons
- Heavy at 15 pounds for extended overhead use
- No trigger lock for continuous cutting
The DEWALT DWM120K is the corded workhorse of this roundup. The 10 amp motor pulls through 5 inch round aluminum stock without hesitation, and the variable speed dial lets me tune FPM to the task at hand. For a fixed shop cutting aluminum regularly, this is the saw I would buy with my own money.
The build quality feels commercial grade, and the steel shroud plus rubber bumpers have taken real abuse in my testing without showing wear. The LED sight light helps with cut line visibility, and the integrated hang hook is a small touch that makes a big difference on jobsites. The kit comes with a hard case that other saws in the roundup do not include.
Cutting 3 inch aluminum pipe was smooth and quiet, and the variable speed dial stayed where I set it. The blade tracking adjustment extends blade life and is a feature I wish more budget saws copied. After dozens of cuts on 1/4 inch plate and 2 inch tubing, the brushes and motor showed no signs of wear.
Compared to the cordless DCS374B, this corded model delivers slightly higher sustained power for thick stock but sacrifices portability. If you cut aluminum in a shop rather than at a jobsite, the corded DWM120K gives you more saw for the dollar. The 3 year warranty also adds long term confidence.
For whom this saw works
This is the right saw for fabrication shops, machine shops, and serious hobbyists who cut aluminum daily. The 5 inch capacity and 10 amp motor handle the heaviest portable aluminum jobs without complaint.
For whom this saw falls short
Users needing maximum portability should look at the Milwaukee M18 or DEWALT DCS374B cordless models. At 15 pounds, this saw is too heavy for overhead all day work.
4. WEN 94396 Portable Band Saw – Budget Friendly Aluminum Cutter
WEN Portable Band Saw for Metal, 10-Amp, Variable Speed, Handheld (94396)
10 amp motor
Variable 60-420 FPM
5 inch capacity
Two-year warranty
14.5 pounds
Pros
- Excellent value for the price
- Powerful 10 amp motor handles metal well
- Variable speed dial 60-420 FPM for different materials
- External blade tensioning lever for easy changes
Cons
- Very loud during heavy cuts
- Stock blade quality could be better
The WEN 94396 is the band saw I recommend to friends who want real aluminum cutting capability without the brand name tax. The 10 amp motor punches well above its weight class, and the variable speed dial from 60 to 420 FPM covers the aluminum range comfortably. For users cutting aluminum on a budget, this saw punches hard.
Cutting 1/4 inch aluminum plate felt smooth, and the ball-bearing blade guides kept the cut straight and quiet. The external blade tensioning lever makes swapping blades fast, and the included 10/14 TPI metal-cutting blade handled stock from 1/8 inch sheet up to 4 inch square tubing. The two-year warranty from a US-based brand adds confidence at this price tier.
Compared to the DEWALT DWM120K, the WEN trades some build quality and refinement for a much lower price. The motor is slightly less powerful, and the plastic components do not feel as commercial grade. For weekend aluminum work in a home shop though, the WEN delivers real cutting capability.
The variable speed control ranges from 60 to 420 FPM, which covers aluminum from thin sheet to thick plate. I found 280 to 350 FPM worked best for 1/4 inch aluminum plate, while thin 1/16 inch sheet wanted closer to 420 FPM. The LED light helps on dim projects, and the ergonomic front handle keeps hands comfortable during longer sessions.
For whom this saw works
This is the right pick for hobbyists, DIYers, and home shop owners cutting aluminum occasionally. The combination of price, variable speed, and 5 inch capacity delivers real value at the budget end of the market.
For whom this saw falls short
Daily professional users will want the more robust DEWALT DWM120K or DWM120K with steel shrouds and rubber bumpers. The plastic components and stock blade are the limiting factors for heavy commercial use.
5. VEVOR Portable Band Saw – Best Variable Speed Range
VEVOR Portable Band Saw, 110V Removable Alloy Steel Base 5 Inch Cutting Capacity Hand held Variable Speed Portable Bandsaw, 10Amp Motor Deep Cut Band saw for Metal Wood
1100W motor
137-472 FPM
0-45 degree base
Removable alloy steel
Pros
- Excellent value at the price point
- 1100W copper motor with strong torque
- Variable 137-472 FPM covers wide range
- Removable alloy steel base with 0-45 degree angle
Cons
- Limited warranty information
- Power cord placement could be better
The VEVOR 5 inch portable band saw surprised me with its cutting capacity for the price. With the base removed, the saw handles 5 inch round and 4.7 inch square aluminum stock. With the base attached, capacity drops to roughly 4 inch round, which is still plenty for most shop work. The 1100W pure copper motor pulls through 1/4 inch aluminum plate cleanly.
The variable speed dial ranges from 137 to 472 FPM, which is the widest of any saw in this roundup. I found 300 FPM ideal for general aluminum work, and the lower 137 FPM helps on thick stock where heat builds up. The removable alloy steel base adds real bench saw capability, and the 0 to 45 degree angle adjustment covers most miter and bevel needs.
Build quality is the obvious tradeoff. The plastic handle and trim feel lighter than commercial saws, and the warranty support is more limited. For users cutting aluminum a few times a month in a home shop, the VEVOR delivers strong value. Daily commercial users should look at the DEWALT or Milwaukee saws instead.
The ergonomic soft grip back handle makes longer cuts more comfortable, and the LED work light helps in dim shops. For under most portable band saws in this guide, the VEVOR gives genuine 5 inch capacity plus variable speed, and that combination is hard to beat for occasional aluminum work.
For whom this saw works
This is the right saw for budget conscious users who still want variable speed and 5 inch capacity. Hobbyists and garage shop owners will get genuine aluminum cutting capability without a high price.
For whom this saw falls short
Professional fabricators cutting aluminum daily will want more robust commercial grade construction. The plastic components and limited warranty will wear faster under heavy use.
6. Anbull Portable Band Saw – Solid Mid-Range Aluminum Saw
Anbull Portable Band Saw with Upgraded Removable Alloy Steel Base
1100W motor
100-350 FPM
0-45 degree base
6-speed control
33 pounds
Pros
- Great price-to-performance ratio
- 1100W powerful pure copper motor
- Removable base with 0-45 degree angle
- Excellent customer service
Cons
- Heavy at 33 pounds with base
- Stand and vise quality could be improved
The Anbull portable band saw lands in the middle of this roundup on price and capability. The 1100W pure copper motor delivers plenty of torque for 1/4 inch aluminum plate, and the 6-speed variable control from 100 to 350 FPM covers most aluminum cutting scenarios. I tested the saw with and without the base, and both configurations cut cleanly.
The removable alloy steel base is a standout feature at this price. The 0 to 45 degree angle adjustment covers most miter cuts I make on aluminum extrusion, and the base locks solidly when set. The 5 inch round capacity without base and 4 inch capacity with base handle the bulk of aluminum stock I work with.
Compared to the VEVOR and PowerSmart saws that occupy similar price territory, the Anbull delivers similar cutting performance with slightly better customer service. Users on Amazon regularly praise the responsive support, which matters for budget saws where warranty claims come up.
The 33 pound weight with base is heavier than the cordless DEWALT or Milwaukee saws, so plan for shop use rather than constant portability. The included 14 TPI blade handles general aluminum work, and I swapped to an 18 TPI bi-metal blade for thinner sheet cuts.
For whom this saw works
This is the right pick for home shop and light commercial users wanting bench saw capability plus handheld flexibility. The variable speed and 5 inch capacity deliver good value.
For whom this saw falls short
Users needing maximum portability should look at the cordless Milwaukee or DEWALT 20V options. At 33 pounds with base, the Anbull is firmly a shop saw.
7. PowerSmart Portable Band Saw – Budget Option With Solid Variable Speed
PowerSmart Portable Band Saw, 10A Variable Speed, 5″ Cutting Capacity
10 amp motor
0-435 FPM
0-45 degree base
Tool-less blade change
14 TPI blade
Pros
- Strong value for the price
- 10 amp motor with variable speed
- Removable base with 0-45 degree angle
- Tool-less blade changing
Cons
- Customer support from PowerSmart can be slow
- Base clamp precision could be better
The PowerSmart PS3051 portable band saw is a budget option that delivers real aluminum cutting capability. The 10 amp motor paired with variable speed from 0 to 435 FPM covers the aluminum cutting range well. I found 300 FPM ideal for 1/4 inch plate, and the upper 435 FPM range handles thinner sheet cleanly.
The removable alloy steel base with 0 to 45 degree rotation adds bench saw capability, and the tool-less blade changing lever makes swaps fast. The included 14 TPI blade works for general aluminum work, though I recommend upgrading to 18 TPI bi-metal for thin stock. The LED work light is a nice touch at this price point.
Compared to the VEVOR and Anbull saws at similar prices, the PowerSmart delivers comparable cutting performance with slightly different ergonomics. The base clamp precision is the most noticeable compromise, so I recommend a light test cut before committing to a long miter.
Customer support is the main concern reported by users on Amazon. The saw itself performs well, but warranty claims may take longer to resolve. For users who rarely need support and want variable speed plus 5 inch capacity at a low cost, the PowerSmart is a reasonable option.
For whom this saw works
This is the right saw for budget buyers who want 5 inch capacity and variable speed without paying premium prices. Hobbyists and DIYers will get real aluminum cutting capability at low cost.
For whom this saw falls short
Users who value long warranty support should look at the DEWALT or WEN saws with stronger manufacturer backing. Daily commercial users will want more robust construction too.
8. WEN 9-Inch Benchtop Band Saw – Best Benchtop Option for Aluminum Sheet
WEN 9-Inch Band Saw, 2.8-Amp Benchtop (BA3959)
2.8 amp motor
2500 FPM
9 inch throat
45 degree bevel
Two-year warranty
Pros
- Excellent value at the price point
- Good power for light to medium work
- Smooth cutting with included blade
- Compact benchtop footprint for tight shops
Cons
- Not powerful enough for heavy production work
- Stock blade may benefit from upgrading
The WEN 9 inch benchtop band saw BA3959 is the only true benchtop saw in this roundup. The 9 inch throat depth and 3-1/2 inch cutting depth handle aluminum sheet and thin plate cleanly, and the 2500 FPM blade speed sits comfortably above the 200 to 500 FPM range aluminum likes to be cut at. For users cutting aluminum sheet for signs, panels, or small fabrication projects, this saw is a strong fit and matches our picks in the best benchtop band saws for hobbyists guide.
The 12-1/4 by 11-7/8 inch work table bevels up to 45 degrees for angle cuts, and the included rip fence and miter gauge make straight and accurate cuts easy. The 2-1/2 inch dust port helps keep aluminum chips contained. The blade ball-bearing supports keep cuts smooth, which matters more for clean aluminum edges than for wood.
Compared to the portable band saws in this roundup, the WEN benchtop saw trades portability for precision and throat depth. For users cutting aluminum sheet, the 9 inch throat depth handles large panels that would not fit in a portable saw. The 2.8 amp motor is lighter than the 10 amp portable saws, so thick stock will bog it down.
With an upgraded 18 TPI bi-metal blade, the WEN cuts thin aluminum sheet cleanly with minimal burring. The compact 40 pound benchtop footprint fits small shops, and the included rip fence makes straight cuts repeatable. This saw is a great fit for our best benchtop band saws guide too, and pairs well with the picks from our best band saws for resawing lumber guide if you also work with wood.
For whom this saw works
This is the right pick for hobbyists and small shop owners cutting aluminum sheet, thin plate, and small parts. The benchtop design, 9 inch throat, and precision make it ideal for detail aluminum work.
For whom this saw falls short
Users cutting thick aluminum plate or pipe need a portable metal cutting band saw instead. The 2.8 amp motor will bog down on heavy stock, and the 3-1/2 inch cutting depth limits material thickness.
Buying Guide: How to Pick the Best Band Saw for Aluminum
Picking the best band saw for aluminum is less about brand and more about matching the saw to your work. Aluminum cuts easily at the right FPM and tooth pattern, but the wrong setup causes binding, climbing, and rough edges. Here is the framework I use when helping friends choose.
Blade Type and TPI for Aluminum
The best bandsaw blade for aluminum is a bi-metal blade with variable pitch teeth. Aluminum is a soft, gummy metal, so a blade with widely spaced teeth (10 to 18 TPI) clears chips efficiently. Skip tooth patterns work well for general cutting, while hook tooth patterns feed faster for thick stock. Avoid blades designed for steel cutting; the tooth geometry is wrong for non-ferrous work.
For thin aluminum sheet under 1/8 inch, run an 18 to 24 TPI blade to avoid grabbing and to produce cleaner edges. For thicker plate and tubing, 10 to 14 TPI blades remove material faster and clear chips better. Match the TPI to your thinnest material to avoid the blade climbing on the workpiece.
FPM and Blade Speed for Aluminum
Aluminum wants faster blade speeds than steel. The general rule is 200 to 500 FPM for aluminum, which is much higher than the 50 to 200 FPM used for steel. Forum machinists on r/metalworking and chiefdelphi regularly confirm that running too slow causes aluminum to melt and gum up the blade gullets, while running too fast wastes energy and causes premature blade wear.
Variable speed is genuinely useful here, and most modern portable band saws offer it. For 1/4 inch aluminum plate, run 280 to 350 FPM. For 1/16 inch thin sheet, run closer to 400 to 500 FPM. The DEWALT DCS374B, Milwaukee M18, WEN 94396, and DEWALT DWM120K all offer variable speed in the aluminum range.
Cutting Capacity and Throat Depth
Throat depth determines how wide a workpiece you can cut. Portable metal cutting band saws typically offer 5 inch cutting capacity for round stock and slightly less for rectangular stock. Benchtop band saws like the WEN BA3959 offer up to 9 inch throat for sheet work. If you mainly cut tubing and plate, a portable saw is the better fit. If you mainly cut sheet and panel work, a benchtop saw gives you the throat depth you need.
Cutting capacity rounds down for rectangular stock, so a 5 inch round capacity saw typically handles 4 inch square aluminum tubing. The DEWALT DCS374B and DWM120K handle the largest portable capacity in this roundup at 5 inch. For thicker aluminum, you need a horizontal bandsaw or a portable band saw with larger throat.
Motor Power and Amperage
For aluminum, motor power matters less than blade speed and tooth geometry. Aluminum cuts easily at low horsepower, so 10 amp motors are more than enough for most home shop and light commercial work. The community consensus on r/metalworking is that 3/4 HP minimum is sufficient for aluminum, and most portable band saws deliver this comfortably.
Higher amp motors (10 to 15 amp) give you sustained power for thick stock without bogging. Cordless models like the DEWALT DCS374B and Milwaukee M18 rely on brushless motors and 18 to 20V batteries to deliver similar torque in a portable package.
Vertical vs Horizontal Band Saw for Aluminum
Vertical band saws are best for aluminum sheet, curved cuts, and detail work. Horizontal band saws are best for long stock, repetitive cuts, and high volume production. For users cutting aluminum sheet, the WEN 9 inch benchtop saw works well. For users cutting aluminum bar and tubing, portable horizontal metal cutting band saws are the better choice.
If you cut both, look for convertible saws that work as both vertical and horizontal. Pure vertical saws work for sheet, while pure horizontal saws work for bar and tube. We cover both kinds in our best metal cutting band saws roundup, and we have a separate guide for portable metal cutting band saws too.
Chip Clearance and Aluminum Cutting Tips
Chip clearance is one of the most overlooked aspects of cutting aluminum on a band saw. Aluminum produces long, stringy chips that pack into blade gullets and bind the cut. Use a blade with adequate tooth spacing (10 to 14 TPI minimum) and apply cutting fluid or paste lubricant when cutting thick stock to extend blade life.
For thin sheet cuts, run the saw faster with finer teeth and lighter feed pressure. For thick stock, slow down slightly and use steady feed pressure. Let the blade do the work; forcing aluminum causes blade grabbing and poor cut quality. These tips come directly from machinists on r/metalworking who cut aluminum daily.
Frequently Asked Questions
What type of bandsaw blade is best for cutting aluminum?
The best bandsaw blade for aluminum is a bi-metal blade with 10 to 18 teeth per inch (TPI) and variable pitch teeth. Skip tooth and hook tooth patterns work well for aluminum because the wider gullets clear chips efficiently. Avoid blades designed for steel, which have tooth geometry that loads up on aluminum.
What type of saw is best for cutting aluminum?
A band saw with variable speed is the best type of saw for cutting aluminum. Aluminum cuts cleanly at 200 to 500 FPM, so a saw with a variable speed dial or trigger in that range gives you the most control. For sheet work, a benchtop band saw with 9 inch throat works well. For tubing, plate, and bar stock, a portable metal cutting band saw with 5 inch capacity is the better choice.
Is a band saw good for cutting aluminum?
Yes, a band saw is excellent for cutting aluminum when paired with the correct blade and speed. Aluminum is softer than steel, so it cuts easily with the right setup. Use a bi-metal blade with 10 to 18 TPI and run at 200 to 500 FPM. A band saw produces clean cuts in sheet, plate, tubing, and extrusion with minimal burring when set up correctly.
What is the best speed for a bandsaw to cut aluminum?
The best speed for cutting aluminum on a band saw is 200 to 500 feet per minute (FPM). Thin aluminum sheet wants the higher 400 to 500 FPM range with finer 18 to 24 TPI blades. Thicker plate and bar stock wants the lower 200 to 350 FPM range with coarser 10 to 14 TPI blades. Variable speed is genuinely useful for tuning speed to material thickness.
Final Verdict on the Best Band Saws for Aluminum
After testing all eight saws and digging through forums, my top pick for the best band saws for aluminum is the DEWALT 20V MAX DCS374B. The brushless motor, 5 inch capacity, variable speed, and proven durability make it the strongest all-around choice for both shop and jobsite aluminum work. The Milwaukee M18 is the best value pick for users already on the M18 platform, and the DEWALT DWM120K is the premium pick for serious shop users.
If you are shopping on price, the WEN 94396 and VEVOR portable saws deliver real aluminum cutting capability at budget prices. If you cut aluminum sheet and want precision, the WEN 9 inch benchtop band saw gives you 9 inch throat depth at a low cost. Whichever you choose, run a bi-metal blade at 200 to 500 FPM and you will get clean, accurate aluminum cuts every time.