I just had a pleasant experience cutting and breaking .025 aluminum. I have done it only on straight lines but tonight I cut 14 nose ribs and deburred them in about two hours.
The trick it seems is to cut rectangular blanks close to the finished size, that I did in a shear, then score the shape with the P-800 Olfa Knife about 10 times. I just took my time and didn’t press real hard.
Blank size was 10” X 14”. Had to be real careful lining up the forming block to make sure it was centered on the 10” dimension. Transferred the holes, drilled em, bolted template to the blank and scored away.
I used flanging pliers to grab the edge and get things started but it broke away clean using only hand pressure. Be sure to wear gloves.
