Cutting thin metal

What would be ur chice of bit for cutting metal 1/16 or smaller?

Andy…Metal: Steel, Aluminum, Brass, Stainless, Gold, Silver, Cast Iron, Zinc, Magnesium, Lead, (I can go on…), but EACH type of metal can also come in a different TYPE of ALLOY and would require different settings, coatings, cutting fluids, cutters…so, how about helping yourself and tell us what kind of metal. (PS: ur = your). OR doing a little bit of research because your question has been asked many times before, OR we can address your question individually IF you can provide us with the missing information.


We have a bit on endmill selection at: and the community has more at:

As @RichCournoyer noted, the specifics of what and how you’ll be cutting are significant — but usually one can do well enough just by starting w/ a carbide endmill and working forward from that as a baseline.

To add a little here…don’t forget workholding, it can be really challenging for thin material that you’re trying to cut something out of.


Mike makes a great point. I’d go as far to say this is as important as the cutting mill. In my early days I always came up against keeping my aluminium in place. These days I either clamp it in a machinists vice or use super glue and tape when it comes to sheet material.

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