Aluminum extrusion and profile cutting
Aluminum extrusions are commonly supplied in long stock lengths, while assemblies need many shorter pieces. Plan compatible extrusion profiles separately and generate a straightforward length-based cutting schedule.
Browser-based · No sign-up · Straight 1D cuts only
Finished parts + cutting allowances + leftover = stock length
What this calculation covers
Enter the lengths and quantity of each aluminum profile you have. Use the same approach for framing extrusion or other straight profiles when the geometry of the cross-section does not affect the length calculation.
The web planner does not consider mitered corner joints, machining allowances, anodized-surface handling or saw-specific clamping constraints.
A real-number cut list example
Four 1,450 mm pieces make 5,800 mm of finished extrusion. If each takes a separate 3 mm cut, total kerf is 12 mm and the 6,000 mm bar leaves 188 mm.
Length balance: 5800 mm finished + 12 mm kerf + 188 mm leftover = 6000 mm stock.
This illustrative example assumes zero head trim and tail reserve. Always enter your actual machine allowances.
How to prepare a cutting plan
Group identical sections
Do not mix 20×20 and 40×40 extrusion, or different alloys, in one optimization run.
Include end trimming
Set a head-trim allowance if supplier stock has damaged or uneven ends.
Check usable remnants
Choose a realistic minimum offcut length for later re-use in your workshop.
Enter stock, parts and saw kerf in the free 1D MetalCut calculator.
Common questions
Can I use aluminum extrusion stock of mixed lengths?
Yes, as long as all stock rows represent the same compatible profile and material.
Does it optimize 45-degree cuts?
No. The online calculation is for straight-length pieces and does not model angled saw cuts.