Electronics > Projects, Designs, and Technical Stuff
Square holes on aluminum.... how do you do it?
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rpetitho:
I used a combination of drills and jigsaws on my isolation transformer enclosure. Worked pretty good for bigger holes. Smaller holes are a different challenge.

-Bob
viperidae:
Square drill bits are just for wood aren't they?
beanflying:
Nibblers for the win on thin sheetmetal and even plastics but you are limited to about 2mm max. The best bit is if you are working in enclosures with other electrical stuff still inside then the chips are way less floaty and easier to cleanup than every other method. Minimal buckling as well on even thin materials over using tin snips or shears.

I would seriously love the money to spare for a set of hydraulic punches but it would be a total indulgence and so drills files and a Dremel for the other jobs.

Tips - Masking tape for the tool side (not the die side) to minimize scratching and buy a deburring tool (the blue handled thing) and use your Laser Cutter to do the mark out for accuracy ;)
EEEnthusiast:
Buy a cheap CNC router machine from China. Something like this

https://www.aliexpress.com/item/32919397764.html?spm=a2g0o.productlist.0.0.54db57f5O012h9&algo_pvid=c1d5f8e0-b557-4959-bcf6-b11b82acb20c&algo_expid=c1d5f8e0-b557-4959-bcf6-b11b82acb20c-7&btsid=e9376042-133e-4e2f-8bca-df0b401da4fa&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_53

It can cut any shape on metal sheets and it is really precise for hobbyist. I have the same one and have cut square holes on 1.6mm thick Aluminium sheets.
GeorgeOfTheJungle:
Three great tools:

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