Aluminum Extrusion Cutter Tool

Our client needed a way to repeatably and precisely trim corner tabs off of pre-made aluminum extrusions. As aluminum is easy to work with, we determined that an inexpensive woodworking router would suit the client’s needs. This was the most economical solution for our client, as this saved on development time.

We fabricated the fixture to accept the standard extrusion from either side. Because the tool would cut two vertical tabs at once, a pair of precise slots were cut in the tool to minimize chatter during the cut. The tool features an integrated depth stop which ensures the cut is consistent each time, from either end of the tool. The tool is double-sided, allowing for cuts on opposing edges of the standard extrusion. This design allows for quick, precise, and safe cutting, perfectly meeting our client’s needs.

We found that the tool worked great, but it created a lot of chips through the evacuation holes in the front and back. We created simple catch bins that lock in place with magnets. After several cuts have been made, these bins can be removed and the chips can be dumped. This keeps the work area clean and safe while using the tool.