Aluminum cutting — sheet, profile, signage
Short answer
Aluminum cutting on our fiber laser in Tbilisi covers 0.5mm to 5mm sheet — a ceiling set by aluminum's high reflectivity and thermal conductivity. We cut sheet, flat bar, signage letters and logos to ±0.1mm positional tolerance. Quotes arrive within 24 hours and the minimum order is 1 piece.
Aluminum is a lightweight, corrosion-resistant metal chosen for signage, facade lettering, enclosures and decorative parts because of its strength-to-weight balance. In laser cutting it behaves differently from carbon steel and stainless: the surface reflects most of the infrared beam and conducts heat away from the kerf quickly, which limits both cutting speed and maximum thickness. That is why we cut it only on a fiber laser, never a CO2 machine. This page collects in one place how thick we actually cut, which stock shapes we accept, how the price is calculated, and when we point you somewhere else.
Key facts
- Maximum thickness (sheet)
- 5mm — fiber laser
- Cleanest range
- 0.5–3mm
- Positional tolerance
- ±0.1mm
- Minimum hole diameter
- = sheet thickness (2mm hole on 2mm sheet)
- Thickness for signage letters
- 1–3mm
- Minimum order
- 1 piece
- Quote turnaround
- 24 hours
- Accepted files
- DXF, DWG, AI, PDF — vector, closed contours
- Production / delivery
- Tbilisi, shipped across Georgia
Why does aluminum need a fiber laser?
Aluminum absorbs a fiber laser's 1064nm beam far better than a CO2 laser's 10600nm beam. With CO2 most of the beam reflects straight back, which makes the cut inefficient and can damage the machine's optics — this is why industrial aluminum cutting is almost always done on fiber-class equipment. The second factor is thermal conductivity: aluminum pulls heat away from the cut line very quickly, so above 3mm the cut slows down and demands more power. Together these two properties are what cap aluminum at a lower thickness than carbon steel.
What thickness of aluminum do we cut?
We cut aluminum sheet from 0.5mm to 5mm at a positional tolerance of ±0.1mm. The cleanest and fastest range is 0.5–3mm — exactly the thicknesses used for signage letters, nameplates, logos and decorative parts, where the edge comes out virtually burr-free. 3–5mm is possible but needs a reduced feed rate and may leave a light scorch mark on the edge. Minimum hole diameter equals sheet thickness: on 2mm aluminum, a hole under 2mm will not cut reliably. We do not cut aluminum above 5mm — for those jobs we point you to a partner workshop.
- 0.5–3mm — cleanest, fastest range
- 3–5mm — possible, slower, light scorch risk on the edge
- Above 5mm — we do not cut it; routed to a partner workshop
- ±0.1mm — positional tolerance
- Minimum hole diameter = sheet thickness
Which aluminum stock shapes do we accept — sheet, bar or tube?
We cut flat aluminum sheet — supplied by you or sourced by us — from your drawing. We also cut flat-laid bar and profile stock, provided the piece sits entirely within the work table. Cutting into the wall of a round tube or hollow profile — decorative openings on a pipe surface, for example — needs a rotary attachment and is not part of our standard workflow; contact us in advance for that kind of job. If you already have aluminum sheet and only need it cut to exact size, that is covered separately on our sheet-metal cut-to-size page.
Why is aluminum the default choice for signage and facade letters?
Aluminum is light, does not rust, and survives outdoors for years — which is why it is the most common metal for volumetric logos and facade lettering. For letters and signs we normally use 1–3mm: 1mm is enough for flat letters and nameplates, while 2–3mm supports the returns of a volumetric letter and its mounting hardware while staying light enough to install on a facade. One distinction matters: solid aluminum sheet and aluminum composite panel (Dibond — two thin aluminum skins over a plastic core) are different materials. We do not laser-cut Dibond, because the plastic core burns in the kerf; it is normally routed on a CNC mill, and CNC milling is not among our services.
How do anodized and polished aluminum behave when cut?
Aluminum sheet comes in mill finish, brushed, matte or anodized. The glossier the surface, the more beam it reflects and the slower the cut — mirror-polished aluminum is always run at a reduced feed rate. On anodized or painted aluminum, colour may shift or the coating may burn off in a narrow band along the cut line; that is a normal thermal side effect, not a defect. If holding exact colour right at the edge is critical for your finished product, we cut one test sample first and show you the result before running production.
How much does aluminum cutting cost?
Four things set the price: total cut contour length, sheet thickness (thicker means slower), who supplies the material — you or us — and batch size. Batch size matters on its own: with a single part the full setup time sits in that one price, while across 50 parts the same setup is spread over all of them and the per-piece price drops sharply. We do not publish a fixed price list, because two parts of identical outer dimensions can differ twofold in cost depending on contour complexity. Send a DXF, DWG, AI or PDF file and you will have an exact figure within 24 hours.
Aluminum thickness ranges — typical use, edge quality and minimum hole
| Thickness (mm) | Typical use | Edge quality | Min. hole | Note |
|---|---|---|---|---|
| 0.5–1 | Signage letters, nameplates, thin decor | Clean, burr-free | 0.5–1mm | Fastest and most common thickness |
| 1–2 | Logos, keychains, interior parts | Clean | 1–2mm | Standard thickness for lettering |
| 2–3 | Facade letters, mounting parts | Clean, light deburring needed | 2–3mm | Cuts slightly slower |
| 3–5 | Structural flat parts | Acceptable, possible light edge scorch | 3–5mm | Upper ceiling of our machine |
| >5 | — | — | — | We do not cut it — routed to a partner workshop |
How it works — step by step
- 1
Prepare the file
Prepare a vector file — DXF, DWG, AI or PDF — with closed contours and dimensions in millimetres. If you only have a sketch or a raster logo, send it and we will convert it to vector.
- 2
Choose thickness and finish
Specify a thickness in the 0.5–5mm range and the surface: mill finish, brushed, matte, anodized or painted. If you already own the aluminum, tell us the sheet dimensions.
- 3
Get a quote within 24 hours
Within 24 hours of receiving the file you get a price calculated from cut length, thickness, material source and batch size. Minimum order is 1 piece.
- 4
Cutting and edge check
We cut on the fiber laser at ±0.1mm positional tolerance and inspect the edge. On parts thicker than 3mm we deburr where needed.
- 5
Pickup or delivery
Collect finished parts in Tbilisi, or we ship by courier to any city in Georgia.
Frequently asked questions
What is the maximum aluminum thickness you cut?
Our fiber laser cuts aluminum sheet from 0.5mm to 5mm at ±0.1mm positional tolerance. 0.5–3mm is the cleanest and fastest range. 5mm is the real ceiling of our machine — we do not cut thicker aluminum.
Can you cut 1mm aluminum?
Yes — 1mm is one of the thicknesses we cut most often. It runs fast and comes off the machine burr-free, which is why we use it for nameplates, flat letters and thin decorative parts. On 1mm sheet the minimum hole diameter is 1mm.
Why fiber laser and not CO2 for aluminum?
Aluminum reflects most of a CO2 laser's beam back, which makes cutting inefficient and can damage the machine's optics. A fiber laser's 1064nm beam is absorbed far better by aluminum, making it the standard choice for metal cutting.
Can you cut aluminum composite panel (Dibond)?
Not with a laser. Dibond has a plastic core that burns in the kerf; such panels are normally routed on a CNC mill, and we do not offer CNC milling. We do cut solid aluminum sheet up to 5mm. If you are unsure which material you have, send us the spec.
What file do I need for aluminum cutting?
A vector file — DXF, DWG, AI or PDF with closed contours and dimensions in millimetres. If you only have a sketch or a raster logo, we can help convert it to vector.
Can I order just 1 aluminum part?
Yes, the minimum order is 1 piece — no batch size or bulk volume required. Note that a single part carries the full setup time in its price, so the per-piece cost drops sharply on larger runs. You get an exact quote within 24 hours.
Does a laser-cut aluminum edge need extra finishing?
In the 0.5–3mm range, usually not — the fiber laser leaves a clean edge on aluminum. At 3–5mm a deburring pass may be needed if the visual standard is high, and we do that as required.
What's the difference between cutting aluminum and stainless steel?
Aluminum is lighter and more reflective, so our maximum thickness on it is 5mm versus roughly 6mm for stainless. In exchange, cutting thin aluminum sheet is often faster. For signage, aluminum is lighter while stainless is harder and more reflective in appearance.