Horizontal Band Saw for Aluminum: 5 Saws and Blades Scored (2026)
Five band saws and metal-cutting blades for aluminum work, compared on motor power, cutting capacity, speed control, base design, and manufacturer warranty.
By WeldGearLab Editorial
Updated October 9, 2026
Cutting aluminum stock, tubing, and extrusions cleanly requires steady feed pressure and the right blade speed to prevent clogging. A dedicated horizontal band saw for aluminum provides a clamping vise, gravity feed, and adjustable blade speed to produce square, burr-free cuts without overheating the workpiece. This guide compares five saws and blades on what each listing states: motor power, cutting capacity, blade speed or tooth pitch, base design, and stated warranty terms.
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Quick picks
- Best Overall MAXXT Band Saw with Base: A 10-amp band saw with a detachable aluminum base, variable speed from 60 to 420 ft/min, ETL listing, and a 1-year warranty. Check price on Amazon
- Best Benchtop Saw WEN BA3959 9-Inch: A 2.8-amp benchtop saw with a 12-1/4 x 11-7/8-inch beveling table, 3-1/2-inch cutting depth, and a 2-year warranty. Check price on Amazon
- Best Bi-Metal Blades FOXBC 64-1/2″ 24 TPI Blades (2-Pack): A 2-pack of 64-1/2-inch bi-metal M42 blades with 8 percent cobalt and 24 TPI for horizontal metal band saws cutting aluminum. Check price on Amazon
- Deepest Throat Benchtop QD-KYOHO QBS9″ 9-Inch: A 9-inch throat benchtop saw with 2 mm steel body, 11-3/4-inch square cast-aluminum table, and a 2-year warranty. Check price on Amazon
Compare the picks
| Model | Gear Score | Capacity or size | Speed or pitch | Power source | Warranty |
|---|---|---|---|---|---|
| MAXXT R2103 | 8.3/10 | 115 mm round with base | 60 to 420 ft/min | 10 A corded electric | 1 year |
| WEN BA3959 | 6.9/10 | 3-1/2 in deep, 9 in wide | 2500 ft/min | 2.8 A AC | 2 years |
| QD-KYOHO QBS9″ | 6.4/10 | 3-1/2 in deep, 9 in wide | 2526 ft/min | 2.5 A AC | 2 years |
| FOXBC 64-1/2 in (2-Pack) | 6.4/10 | 64-1/2 x 1/2 in | 24 TPI | Manual blade | Not stated |
| Starrett Duratec SFB | 6.2/10 | 64-1/2 x 1/2 in | 6 TPI | Manual blade | Not stated |
Specifications are manufacturer rated, as published on each listing and collected 9 October 2026.
The picks
| Award | Product | Gear Score About the Gear ScoreThe Gear Score runs from 0 to 10 and weighs performance (35%), build (25%), value (25%), safety (10%, where it applies) and warranty (5%), using only what the manufacturer and the listing publish. How we pick › | |
|---|---|---|---|
MAXXT Band Saw with Lightweight Aluminum Base
|
8.3/10 | Check price on Amazon | |
WEN 9-Inch Band Saw, 2.8-Amp Benchtop (BA3959)
|
6.9/10 | Check price on Amazon | |
Band Saw, Portable 9-Inch Bandsaw for Woodworking
|
6.4/10 | Check price on Amazon | |
FOXBC 64-1/2" x 1/2" x 0.02" x 24 TPI Metal
|
6.4/10 | Check price on Amazon | |
Starrett Duratec SFB Band Saw Blade
|
6.2/10 | Check price on Amazon |
MAXXT Band Saw with Lightweight Aluminum Base
A 10-amp horizontal band saw with an aluminum base, variable speed from 60 to 420 ft/min, ETL listing, and a 1-year warranty.
Pros
- Detachable aluminum base allows horizontal benchtop use with auto-stop
- Variable blade speed from 60 to 420 ft/min for aluminum and steel
- Listed to ETL and OSHA specifications
- Stated 1-year limited warranty
Cons
- Spec table states blade length as 11.5 centimeters, an obvious listing error
- Spec table lists speed as 420.01 rpm rather than blade feet per minute
- Base cut capacity is limited to 115 mm round and 100 x 100 mm square tube
- Heavier setup than standalone handheld portable band saws
WEN 9-Inch Band Saw, 2.8-Amp Benchtop (BA3959)
A 2.8-amp benchtop band saw with a 12-1/4 x 11-7/8-inch beveling table, 3-1/2-inch cut depth, and a 2-year warranty.
Pros
- Spacious 12-1/4 x 11-7/8-inch work table bevels up to 45 degrees
- Cuts up to 3-1/2 inches deep and 9 inches wide
- Includes rip fence, miter gauge, and 2-1/2-inch dust port
- 2-year manufacturer warranty stated in the listing
Cons
- Spec table recommends wood surface, requiring a fine-tooth blade for aluminum
- Spec table lists speed as 2500 rpm while bullets state 2500 feet per minute
- Spec table lists dimensions as 11 x 7 x 4 inches, which contradicts table size
- No electrical safety certification stated
Band Saw, Portable 9-Inch Bandsaw for Woodworking
A 2.5-amp benchtop band saw with a 2 mm steel body, cast-aluminum bevel table, and a 2-year warranty.
Pros
- Cast-aluminum table tilts 45 degrees right and 5 degrees left
- 2 mm steel plate construction with powder-sprayed finish
- Quick-release blade tensioning and tool-free guide adjustment
- 2-year warranty stated in the listing
Cons
- Voltage contradiction: bullets state 120 V while spec table lists 110 V
- Speed contradiction: bullets state 2526 FPM while spec table lists 770 rpm
- Surface recommendation lists wood, requiring metal-cutting blade for aluminum
- No electrical safety certification stated
FOXBC 64-1/2" x 1/2" x 0.02" x 24 TPI Metal
A 2-pack of 64-1/2-inch bi-metal M42 blades with 8 percent cobalt and 24 TPI for horizontal metal band saws cutting aluminum.
Pros
- Bi-Metal M42 construction with 8 percent cobalt content
- 24 TPI pitch suits thin-wall aluminum tubing and sheet
- Fits common 4 x 6 horizontal band saws using 64-1/2 x 1/2-inch blades
- Includes 2 blades per package
Cons
- No warranty term stated in the listing
- Fine 24 TPI tooth pitch cuts slower in thick solid aluminum billets
- Spec table lists Unit Count as 1 Count while Number of Items states 2
- No safety certification stated
Starrett Duratec SFB Band Saw Blade
A 64-1/2 x 1/2-inch carbon steel blade with 6 TPI regular tooth and raker set for cutting aluminum and nonferrous metals.
Pros
- 6 TPI regular tooth with raker set clears chips in thicker aluminum
- Fits horizontal and vertical band saws taking 64-1/2 x 1/2-inch blades
- Flexible carbon steel back permits re-welding on standard welders
- Made by Starrett with 140-year toolmaking history
Cons
- Thickness contradiction: title states .025 inch while spec table says 0.03 inches
- Carbon steel wears faster than bi-metal M42 on tough cuts
- 6 TPI is too coarse for thin-wall aluminum tubing under 1/8 inch
- No warranty term stated in the listing
How we scored them
Each saw and blade is scored out of 100 on performance, build, value, safety listing and warranty, with the weights published on our How We Pick page. Machines with electrical safety certifications earn safety points, while unlisted tools and blades score zero on that criterion; the ranking comes from the stated specifications.
| Product | Gear Score | Perf. /35 | Build /25 | Value /25 | Safety /10 | Warranty /5 |
|---|---|---|---|---|---|---|
| MAXXT Band Saw with Base | 8.3 | 32 | 20 | 21 | 8 | 3 |
| WEN BA3959 9-Inch | 6.9 | 24 | 20 | 21 | 0 | 3 |
| QD-KYOHO QBS9″ 9-Inch | 6.4 | 23 | 19 | 19 | 0 | 3 |
| FOXBC 64-1/2″ 24 TPI Blades (2-Pack) | 6.4 | 28 | 20 | 20 | 0 | 0 |
| Starrett Duratec SFB 64-1/2″ Blade | 6.2 | 24 | 19 | 19 | 0 | 0 |
Buying guide: what matters in a horizontal band saw for aluminum
Cutting speed and variable control
Aluminum cuts best at higher blade speeds than steel, but running too fast generates excess heat that gums up blade teeth. A saw with variable speed control lets you match blade feet per minute to the alloy and section thickness. The MAXXT listing provides variable speeds from 60 to 420 ft/min, allowing operators to slow down for solid bars or speed up for thin profiles. Benchtop vertical saws run at fixed speeds above 2500 ft/min, which suit thin metal sheets and wood but require careful feed control to prevent blade loading.
Horizontal base versus benchtop vertical saws
A true horizontal band saw rests on a pivot frame with an integrated vise, allowing gravity or a feed mechanism to pull the blade downward through clamped metal stock. This setup keeps cuts square and frees your hands during the cut. Benchtop vertical saws require manual feeding against a miter gauge or rip fence on a tilting table. While vertical saws offer generous throat depths for curved sheet cuts, a horizontal base holds structural tubing and solid bar stock far more securely.
Blade tooth pitch and bi-metal material
Choosing the correct tooth pitch prevents stripped teeth and stalled cuts. Thin-wall aluminum tubing and structural channels require finer tooth pitches, such as 14 to 24 TPI, so at least three teeth contact the metal wall simultaneously. Thick aluminum billets and solid bars clear chips better with coarse 6 to 10 TPI blades. Bi-metal M42 blades with 8 percent cobalt resist tooth dulling and heat buildup far longer than conventional carbon steel blades when sawing aluminum alloys.
Work clamping and miter angles
Aluminum workpieces tend to chatter if they are not clamped firmly close to the cut line. Saws with built-in vise jaws support miter cuts from 0 to 45 degrees without requiring separate clamps. A built-in vise prevents aluminum extrusions from spinning or catching when the blade breaks through the bottom edge of the profile.
Chip clearing and lubrication
Soft aluminum tends to weld itself to saw teeth when friction increases. Saws equipped with self-cleaning brushes or chip sweepers help keep blade gullets open. Applying a wax stick or cutting lubricant along the blade path prevents chip buildup, extends blade life, and produces smoother cut faces on aluminum profiles.
Use as directed. Secure aluminum stock firmly in the vise before starting the cut, keep hands away from the moving blade, and wear safety glasses to guard against flying chips. Never leave a running saw unattended, and inspect blades for cracked welds or missing teeth before operation. See our Safety Disclaimer.
Frequently Asked Questions
What is the best band saw for cutting aluminum?
The best saw depends on whether you cut structural profiles or sheet metal. A horizontal band saw with an integrated vise and variable speed control provides the cleanest, squarest cuts on aluminum tubing and solid round bar. For curved cuts in aluminum plate, a benchtop vertical band saw with a fine-tooth metal blade offers greater throat clearance.
What is a horizontal band saw?
A horizontal band saw features a cutting head and blade loop mounted on a horizontal pivot arm above a clamping bed. The blade lowers horizontally through the workpiece, guided by ball bearings and supported by gravity or an adjustable feed cylinder. This design is built specifically for cutting structural metal stock squarely and automatically.
Do all horizontal band saws cut aluminum?
Most horizontal metal band saws can cut aluminum if equipped with the proper blade. Because aluminum is softer than steel, it requires adequate blade speed and sufficient chip gullet clearance to prevent teeth from packing with swarf. Installing a bi-metal blade with 10 to 24 TPI matches the saw to aluminum tubing and solid bars.
How to use metal cutting band saw equipment?
Clamp the aluminum workpiece securely in the vise and adjust the blade guides as close to the cut as possible. Select a blade speed suitable for the material thickness, start the motor before touching the blade to the work, and allow the blade to feed smoothly without excessive downward force. Use cutting lubricant on thicker aluminum sections to prevent tooth loading.
Related: best horizontal band saw, metal fab tools, cold saw for metal, what is a cold saw, best cold cut saw, and best angle grinder for cutting metal.
About the author
WeldGearLab Editorial is the editorial team behind WeldGearLab. We research product listings, specifications, safety listings and warranty terms, score every pick with the published Gear Score method, and correct errors when readers report them. We do not run our own shop trials; see How We Pick for exactly how picks are made.