Drilling Aluminium: Best Drill Bits to Use & Top Tips for Clean Cuts
Avoid clogging, overheating, and poor finishes — here’s how to drill aluminium the right way.
Drilling aluminium can be smooth and hassle-free — if you use the correct drill bit and technique. But use the wrong gear, and you could end up with melted metal, gummed-up drill bits, or damaged workpieces.
Whether you’re working on car panels, trailers, signage, or aluminium castings, this guide will show you how to get clean, accurate holes — and which drill bits work best for aluminium.
Best Drill Bit for Aluminium? Use Cobalt
Aluminium is a soft metal, but don’t let that fool you. It melts at just 660°C, and the chips can fuse onto your bit if it gets too hot — especially when drilling thicker sections.
That’s why standard HSS (high-speed steel) bits can struggle.
👉 Cobalt drill bits are the better choice because:
They dissipate heat faster
They’re more resistant to wear
They reduce chip welding and improve hole quality
We recommend TTP HARD cobalt drill bits (5% cobalt content)
✅ Clean drilling through aluminium sheet or cast
✅ Available in Metric & Imperial sizes
✅ Also suitable for stainless, steel, and cast iron
📦 Buy Metric Cobalt Drill Bits
📦 Buy Imperial Cobalt Drill Bits
5 Drilling Tips
1. Use the Right Drill Bit
Standard HSS bits can work for very thin aluminium, but they heat up quickly and wear out fast.
Use a cobalt drill bit with at least 5% cobalt (like TTP HARD). It stays cooler, lasts longer, and produces a cleaner finish — even in thicker or cast aluminium.
2. Use the Correct Drilling Speed
Too much speed = too much heat. And heat is your enemy when drilling aluminium.
👉 Aim for 200–300 RPM depending on your drill bit size.
📊 Use our Drill Bit Speed Chart to guide your setup.
3. Apply Light, Consistent Pressure
Pushing too hard increases friction and risks clogging your bit. Let the bit do the work.
✅ Pull out regularly to clear chips
✅ Avoid leaning into the drill
4. Always Use a Cutting Lubricant
Lubrication reduces friction and prevents aluminium from sticking to the bit.
🧴 Recommended: TTP CUT-IT Premium Metal Cutting Paste — thick, efficient, and designed for metal.
5. Don’t Forget Safety
✅ Wear safety goggles
✅ Clamp your workpiece
✅ Clear chips often to avoid jamming or kickback
Common Questions (FAQs)
Q. Do I really need cobalt bits for aluminium?
A: You can use standard bits, but cobalt bits drill faster, cleaner, and resist heat buildup — especially for thicker or multiple holes.
Q. Will cobalt bits work on other metals too?
A: Yes. TTP HARD cobalt bits also drill stainless steel, cast iron, mild steel, and harder alloys.
Q. What makes TTP HARD cobalt bits different from cheaper options?
A: TTP HARD cobalt bits are made with 5% cobalt (M35 grade), which means better heat resistance and longer life. They’re precision-ground, designed for professional use, and backed by real-world reviews — not just factory specs.
Looking to invest in a Full Set Of TTP HARD cobalt Drill Bits? We have Imperial and Metric (Small and Large Kits)
Trusted by Tradespeople
BEST METAL DRILL BITS I HAVE EVER USED
These are by far the best metal drill bits I have ever used hands down. I hesitated to purchase these bits for a while because of the price but finally pulled the trigger and can sayI was stupid for not buying them right away. If your thinking of buying these but are hesitant because of the price do yourself a favour and get them, you will save time and money in the long run.
DRILLING EXHAUST MANIFOLD STUDS
They are fabulous. I still haven’t had the time to use them for their actual intented purpose – drilling out exhaust manifold studs, but I did try them on a couple of bolts to see how they did and was very impressed! Told a bunch of my friends about them. Hoping to get a joint order together. I want more sizes or one of the sets!
🎥 Watch: General Tips for Drilling Aluminium (Not Our Bits, But Helpful)
💡 Want smoother, faster results than standard bits? Then Check Out Our Cobalt Drill Bits For Aluminium
We ship to Australia 🇦🇺
