[diviney]

We also have both a chop saw and a horizontal bandsaw. I completely agree that the horizontal bandsaw generally does not make precise square cuts.

In my opinion however, the chop saw is just plain dangerous particularly for students who do not always pay close attention to details. Absolutely - clamping the piece (no round pieces), but try as you may, clamping is not always as secure as it should be. Bullets of metal... plus, where do the broken carbide teeth wind up???

We use the horizontal bandsaw almost exclusively (and yes, sometimes some clean-up / filing is required). There are a few rare occasions where we call on the chop saw, but mostly our adults do those cuts (or VERY closely supervise).

I just feel even at best, the safety of a chop saw used for aluminum is marginal.