Aluminum composite panels are easy to cut, but to ensure a clean edge and prevent scratches on the visible surface, you need to use the right tool and follow a few guidelines. We’ll explain how to cut them with a saw, a guillotine, and a CNC machine, and how to mill them for bending.
Cutting a composite panel with a circular saw
For straight, vertical, or horizontal cuts, use table saws, frame saws (wall saws), or hand-held saws with a guide:
- Maximum cutting speed of about 5,500 rpm and feed rate of up to 30 m/min.
- A carbide disc with a diameter of 200 to 350 mm, with as many teeth as possible featuring a trapezoidal or flat geometry.
- Pitch of 10 to 12 mm and thickness of 2 to 4 mm, with a positive rake angle of about 10° and a clearance angle of 15 to 17°.
- For angle cuts, tilt the panel or the disc.
Using a saw with a cutting depth of 55–65 mm, you can cut several panels at once, as long as the blade enters from the front and exits from the back: this ensures a clean front edge.
Cut with a guillotine
The composite panel can also be cut with shears or a hydraulic guillotine, with a cutting angle of less than 1.5°. To prevent marking the visible surface, place a protective rubber strip between the machine’s cutting blade and the sheet. Adjust the clearance between the blades so that the edge does not become rounded.
CNC Cutting and Milling
For facade components, curved contours, openwork, or trays, a CNC router is the best option: it cuts and, in the same pass, mills the folding grooves. Approximate speeds:
| Core and Operation | Rotation (rpm) | Feed Rate (mm/min) |
|---|---|---|
| FR · cut | 20,000–22,000 | 8,000–10,000 |
| FR · milling | 22,000–24,000 | 10,000–12,000 |
| A2 · cut | 24.000 | 12,000–15,000 |
| A2 · Milling | 24.000 | 15,000–18,000 |
The mineral core of the A2 panel causes greater tool wear, which is why diamond (PCD) cutters are used.
Milling for Bending
To bend the panel, a groove is milled on the back side, the core is removed, and the outer sheet is left with about 0.8 mm of material. Depending on the shape of the groove, different bends are achieved:
- Round slot: 90° bends.
- V-groove: 135° bends.
- Arched slot: 180° folds (not on panel A2).
Learn more about our composite panel machining service.
Mistakes to Avoid
- Cutting without chip removal: The saws must be equipped with a reliable dust extraction system.
- Do not ignore the direction of the film: cut and assemble all the pieces so that the arrows on the film point in the same direction, or there will be differences in tone.
- Drag the panels across the table: hold them on their edges to avoid scratching the visible surface.
- Removing the film too early: Leave it on until the editing is complete (and remove it within one month).
If you’d prefer to receive the pieces pre-cut, we can provide you with composite panels that are cut to size, milled, and folded—ready for installation. And if you’re thinking about an interior renovation, check out how to cover old tiles with aluminum panels.