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Tips on cutting LED profiles and covers

Tips on cutting LED profiles and covers

Our LED channels are typically supplied in 2m (6.56ft) or 3m (9.84ft) lengths. You can easily cut these profiles to length by hand or by machine. Let's see how to do it...

Firstly, what length will you cut? LED strips that are used in these profiles have predetermined cutting increments. This should be taken into account when determining the length you want your profile cut to. Ideally, you want to cut your profile only slightly longer than the LED strip to avoid dark zones. But don't cut your profile exactly the same length as the LED strip, because you need to allow for the endcaps to be fitted, and the supply cable to be attached.

For cutting by hand you need:

  • a hacksaw with a fine cutting blade
  • masking or painters tape
  • a pen or a pencil
  • measuring equipment
  • a compound square for angled cuts

We have found that taping the cover in place in the profile makes it easier to cut by hand and by power tool. It is also easier to mark the tape than marking the LED profile or cover. Another advantage of using tape is that it helps to prevent accidental scratches or splintering.

Once you have measured and marked your profile and cover, it is easy to cut with a fine cutting blade in a hacksaw. With some larger LED profiles - such as our DPL55-FL suspended lighting profile - it may be easier to cut the cover separately from the profile, but the masking tape is still used for marking.

For power cutting, we recommend using a miter saw with a Non-Ferrous Carbide blade to cut aluminum profile and cover together. If we want to cut the cover separately, we use an OSB/Plywood blade for the cover and a Non-Ferrous Carbide blade for the aluminum. We recommend always using the appropriate safety gear such as safety goggles.

For your convenience Wired4Signs USA can cut our LED profiles according to your requirements. And yes we can cut them to any angle you require. Note your request in the comment box when you check out.

Please note that we cannot refund or replace LED profiles and covers that have been cut.

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