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How to Mill Aluminium with a Router – A Step-By-Step Guide

How to Mill Aluminium with a Router

Do you want to mill aluminum but don’t have access to a dedicated machine? If so, you can use a router to mill aluminium. It’s not as difficult as it may sound! With the right tools, knowledge, and safety precautions, you can mill aluminium pieces in your own home or workshop. This guide will take you through the steps for how to mill aluminum safely and efficiently with a router.

Step 1: Gather Your Supplies

Start by gathering the supplies that you will need for this project. You will need an endmill bit made of carbide steel, an adjustable clamp, a drill press vice, some sort of lubricant (such as WD-40), and eye protection. Additionally, it is important to make sure that your router is powerful enough to cut through aluminium; if not, consider investing in one that is more robust.

Step 2: Secure Your Workpiece

Once you have gathered your supplies and determined that your router is suitable for this task, secure the workpiece into the adjustable clamp or drill press vice, depending on what kind of material you are working with. Make sure that your workpiece is tight against the clamp or vice so that it does not shift during the process. Once secured in place, lightly lubricate the area where the endmill bit will be cutting so that it moves more smoothly over the surface of your workpiece.

Step 3: Begin Cutting

Now that everything is properly set up and secure, begin cutting slowly into your workpiece using a smooth back-and-forth motion. Make sure to keep the pressure equal on all sides while cutting; this will help ensure an even finish on all edges of your piece. As you are milling away at your workpiece, be sure to keep an eye out for any signs of heat build-up or excessive wear on your endmill bit; both are signs that it may be time to replace or upgrade your bit! Additionally, always remember to wear proper safety gear, such as gloves and eye protection, while operating machinery like routers or drills.


Milling aluminum with a router is not only feasible but also relatively easy with the right tools and techniques! By following these steps outlined above—gathering supplies, securing the workpiece correctly in either a drill press vice or adjustable clamp, and lubricating appropriately before beginning cutting motions—you can safely create precise cuts into various pieces of metal, including aluminium, from the comfort of your own home or workshop! So get out there and give it a go!

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