How to Cut & Fold Sheet Aluminium





Introduction: How to Cut & Fold Sheet Aluminium

This instructable shows how sheet aluminium may be cut using nothing but a knife and a metal straight-edge.

A simple metal-folder, suitable for making small metal boxes and chassis, is also described.

Step 1: Cutting Aluminium Sheet

Sheet aluminium can be cut without the need for a guillotine or tin-snips which tend to deform the metal.

With the aid of a straight-edge and a sharp knife "score" BOTH sides of the aluminium sheet. This weakens the aluminium and creates a "fracture line".

Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. Flip the sheet over and repeat. After a few "wiggles" the sheet will fracture along the cut-line leaving a clean break as shown in the above photos.

With care and patience full-size sheets of aluminium can be cut using this method. Create a long fracture-line then progressively bend the sheet from one end to to the other.

Step 2: Folding Aluminium

The metal-folder is made from two right-angle sections of metal. My folder is made from aluminium but "angle-iron" is okay.

The spacing between the two nuts and bolts determines the maximum width sheet that can be bent.

Prepare your work:

Mark where you want your bends.

Remove any unwanted corners.

Fold the aluminium:

Now slip the aluminium sheet between the two angle-s and roll the bender forwards while exerting downward body-weight pressure until the fold is 90 degrees.

Step 3: Corner Folds

Make a slot along one edge of your folder to accommodate the first bend.

Position the first fold such that it will enter the slot when the bend is complete.

Complete the bend.

The completed corner is shown in the last two photos.

Key point

When folding edges (see first photo) it is the edge that is placed in the bender ... not the sheet itself.

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    use ful tips. thank you,

    You're welcome :)

    Dear Sir,

    Now I have completed the board. When I tested the operation, I found all good in either x direction or Y direction. When I try diagonal movement, the head part is not moving freely. it makes some rediculas vibration and not moving properly. What could be the reason ? due to Timming belt tension ? or the idler pulley tightness ?

    Please reply.

    Thank you,


    If you do an edit or re-write of this, you might change your spelling of Aluminum by removing the last "I" in your spelling. Thanks.

    "Aluminium" is the British word,
    "Aluminum" is the American word, both are correct.

    Interesting, for DIY works instead using a pro circular saw

    That's a really clever use of aluminum I-beam that's been cut in half. Did you make that yourself or find it in it's current state?

    I found a length of angle in a scrap yard many years ago and made it myself.

    Just cut two equal lengths and drill two holes for the bolts.

    I drilled the holes at least 25mm below the top edge so the full length of the bender can be used to form a lip when making radio chassis.

    The reason for so many slots is to accommodate different width radio chassis. I always bend the two longer sides then bend the shorter sides which means I need two slots.

    Could you post an action shot of the "Fold the aluminium" section? I'm having trouble visualizing it. Thanks!