When it comes to precision metal fabrication, laser cutting is one of the most efficient and accurate methods available. It’s fast, clean, and capable of creating intricate designs with tight tolerances. However, when it comes to cutting aluminum, there are a few key factors to understand before getting started.
At Lindsay Machine Works, we specialize in advanced cutting solutions, including CNC laser, plasma, and waterjet cutting, allowing us to handle all types of materials — including aluminum. Here are five important things you need to know about laser cutting aluminum.
Aluminum Reflects Light and Heat 
One of the biggest challenges in laser cutting aluminum is that it’s highly reflective. Aluminum surfaces can reflect the laser beam, which may interfere with the cutting process or even damage equipment if not properly managed.
That’s why professional-grade laser systems, like those used at Lindsay Machine Works, are designed with fiber laser technology and protective optics that safely handle reflective materials.
Tip: For best results, it’s important to use a laser system specifically configured for reflective metals such as aluminum, brass, and copper.
Laser Power and Thickness Matter
Not all aluminum is the same — and thickness plays a major role in determining cutting speed and quality.
-
Thin aluminum sheets (under 1/8 inch) can be cut quickly with lower laser power.
-
Thicker aluminum (1/4 inch or more) requires higher wattage and slower cutting speeds to maintain accuracy and prevent burrs or rough edges.
At Lindsay Machine Works, our team adjusts laser power, feed rate, and focus based on the specific thickness and alloy, ensuring a clean, consistent cut every time.
Tip: If you’re working with thicker aluminum, it may be worth comparing laser cutting to waterjet cutting, which handles thicker materials without heat distortion.
Laser Cutting Aluminum Produces Minimal Waste
Laser cutting is incredibly precise and efficient, which means less material waste compared to traditional cutting methods.
The laser beam produces a narrow kerf (cut width), allowing parts to be nested closely together during production. This not only saves raw material but also reduces finishing time — making it a cost-effective solution for both prototyping and mass production.
Tip: Pairing efficient laser cutting with expert CNC machining or fabrication can further streamline production and minimize material waste.
The Right Gas Makes a Difference
During laser cutting, assist gases (such as nitrogen or oxygen) are used to blow molten metal away from the cut and protect the laser lens.
-
Nitrogen helps produce clean, oxidation-free edges, which are ideal for parts that need to be welded or painted later.
-
Oxygen increases cutting speed but can slightly oxidize the edge.
At Lindsay Machine Works, we choose the appropriate assist gas depending on the finish and purpose of your aluminum part — balancing speed, precision, and edge quality.
Tip: If you need a polished edge or plan to weld the material, nitrogen-assisted laser cutting is usually the best option.
Laser Cutting Is Part of a Complete Manufacturing Process 
Laser cutting aluminum is just one step in the fabrication process. After cutting, parts may require machining, forming, welding, or finishing to meet final specifications.
That’s why it’s beneficial to work with a full-service shop like Lindsay Machine Works, where we can handle everything in-house — from precision cutting to machining and assembly.
Our goal is to deliver not just accurately cut aluminum parts, but ready-to-use components that meet your project’s performance and quality standards.
Tip: Ask about combining laser cutting with our CNC machining and fabrication services for a complete production solution.
Why Choose Lindsay Machine Works for Aluminum Laser Cutting?
With decades of experience serving industries across the Midwest, Lindsay Machine Works provides precision, reliability, and versatility in every project.
Our advanced laser cutting systems deliver high-quality results on aluminum and other metals, while our in-house expertise ensures your parts are produced efficiently and to specification.
Whether you need one prototype or a full production run, we’ll help you choose the right cutting method — laser, waterjet, or plasma — for your material, design, and budget. Ready to start your next aluminum project? Call us at (816) 257-1166 or visit LindsayMachineWorks.com
