Cutting metal at home used to require a workshop full of heavy machinery. Today, you can achieve professional results using the desktop tools already sitting on your craft table. Whether you are making custom jewellery, serial number plates, or architectural models, 1mm aluminium is the perfect thickness for hobbyist machines. It is sturdy enough to hold its shape but thin enough to yield to a blade or laser. Here is a quick guide on how cut 1mm aluminium sheets on the four most popular desktop platforms.
Skip to the Good Stuff
- Getting started
- How to Cut 1mm Aluminium with Cricut (Maker & Maker 3)
- How to Cut 1mm Aluminium with Siser (Juliet & Romeo)
- How to Cut 1mm Aluminium with Silhouette (Cameo 4 & 5)
- How to Cut 1mm Aluminium with Home Lasers
- Essential Finishing Steps
- Add to basket
- Important Disclaimer
The Golden Rule: Use the Right Material
Standard sheet metal from a DIY shop often contains burrs or uneven tempers. For desktop machines, always use anodised aluminium or specially levelled craft aluminium. This ensures the surface is flat and prevents the blade from skipping.
1. How to Cut 1mm Aluminium with Cricut (Maker & Maker 3)
Cutting 1mm aluminium with a Cricut requires the right tools and a patient approach. While the machine cannot cut through in a single pass, you can achieve professional results by following these steps:
- Prepare the Tool: Equip your machine with a Deep-Point Blade. For decorative work rather than full cuts, use the Engraving Tool.
- Select Settings: In Design Space, choose the Aluminium Sheet or Tooling Leather material setting. Set the pressure to High.
- Secure the Sheet: Place your aluminium on a StrongGrip (Purple) Mat. Crucially, secure all four edges with masking tape to prevent the metal from sliding during the process.
- Execute the Cut: Instead of one heavy pass, use a multi-cut approach. Allow the machine to perform 8 to 12 light passes.
- Finish: Once complete, carefully remove the tape and peel the protective film to reveal your clean, custom-cut design.
2. How to Cut 1mm Aluminium with Siser (Juliet & Romeo)
Siser high-definition cutters boast impressive motor strength, but 1mm is the absolute limit for their blade systems. Rather than a clean through-cut, the process relies on a “score and snap” technique. Follow these steps for the best results:
- Select the Correct Blade: Install a 60° Wedge Blade into your Siser cutter. This steeper angle provides the necessary precision and strength for metallic surfaces.
- Adjust Machine Settings: Set your Force between 25 and 30 and keep the Speed low (5 to 10). A slow, steady pace ensures the blade maintains a consistent line without slipping.
- Set the Passes: Configure your software to perform 2 passes. This creates a deep enough groove in the aluminium to facilitate a clean break.
- Snap the Material: Once the machine finishes, remove the sheet. Gently wiggle the aluminium back and forth along the score line until it snaps cleanly.
3. How to Cut 1mm Aluminium with Silhouette (Cameo 4 & 5)
The Silhouette Cameo series utilizes a high-force carriage (Carriage 2) specifically designed for handling thicker materials. By using the correct blade and software adjustments, you can achieve precise results on 1mm aluminium. Follow these steps to prepare your project:
- Install the Right Blade: Insert a 2mm or 3mm Kraft Blade into Carriage 2. This carriage provides the necessary downward pressure for metal fabrication.
- Adjust the Software: Within the Silhouette Studio settings, enable the Overcut feature. This ensures the blade travels slightly beyond each line so that your corners meet perfectly.
- Configure Blade Depth: Set your manual blade depth between 10 and 15. It is often best to start shallow and increase depth if necessary.
- Set Force and Speed: Choose a Force of 20 to 25 and keep the Speed at 1 or 2. A slow pace prevents the blade from dragging or skipping.
- Execute Multiple Passes: Set the machine to perform 5 passes. This gradual approach ensures a clean cut without straining the motor.
4. How to Cut 1mm Aluminium with Home Lasers
Laser cutting delivers the cleanest finish, but your success depends entirely on your machine’s wattage and laser type. Popular home models like the xTool P2 or xTool F1 offer the power required for this task, whereas standard diode lasers serve different purposes.
- Identify Your Laser: If you own a 10W or 20W Diode Laser, please note these cannot cut 1mm aluminium. They are, however, excellent for engraving the surface by removing anodised coatings.
- Use High-Power Models: For a full cut, use a CO2 laser (like the xTool P2) or a Fibre laser.
- Apply Correct Settings: On a 55W xTool P2, set your Power to 100% and keep the Speed very low (1 to 3 mm/s).
- Manage Passes: Perform 1 to 2 passes to ensure the beam penetrates the material fully.
- Prioritise Safety: Always enable Air Assist. This crucial feature blows away molten metal debris, which prevents scorching and protects your laser lens.
Essential Finishing Steps
No matter which machine you use, the edges of 1mm aluminium will be sharp.
- De-burring: Use a fine-grit sanding block (400 grit) or a specialised de-burring tool to smooth the edges.
- Cleaning: Wipe the metal with isopropyl alcohol to remove oils or adhesive residue from the cutting mat.
- Safety: Wear eye protection when snapping scored metal because tiny shards can fly.
By slowing down your speed and increasing your passes, you can transform your desktop cutter into a miniature metal fabrication shop. Start with a small test square to find your specific machine’s ideal settings before launching into your final project.
Shop 1mm Aluminium Sheets | Full Armour
Complete your craft with our high-grade 1mm aluminium, specifically chosen for hobbyists and professionals.
- Dual-Sided Protection: Arrives with plastic coating on both sides to ensure a scratch-free finish.
- Easy to Work: Naturally rust-resistant and perfect for engraving, sublimating, or custom metal stamping.
- Precision Sizes: Available in 4″x4″, 7″x5″, and 8″x8″ cuts to minimise waste.
- No minimum order: Whether you need a single sheet for a DIY project or bulk for business, we’ve got you covered.
Order today for a lightweight, durable solution perfect for jewellery, signage, and bespoke fabrication!
Important Disclaimer
The technical advice and cutting settings provided are for informational purposes only. Cricut®, xTool®, Siser® and Silhouette® are trademarks of their respective owners. Full Armour is not affiliated with, endorsed by, or sponsored by these brands. Every machine is calibrated differently; therefore, you follow these suggestions at your own risk. Full Armour is not held accountable for failed cuts, wasted material, or damage to machinery. Furthermore, we accept no liability for personal injury or property damage resulting from these techniques. Always consult your manufacturer’s manual for specific safety protocols. By using this guide, you acknowledge full responsibility for your own safety and the maintenance of your equipment.