Aluminum extrusion is a process that is utilized extensively in the manufacturing industry for the purpose of creating components that have a cross-sectional Aluminum Profile that is consistent throughout. Aluminum is used because of its ductility, mechanical strength, and cost-effectiveness in a variety of applications. A die (a specialized tool used to shape material) that has been designed and manufactured to create the desired cross-section is used to shape the aluminum, and then the aluminum is forced through the die. Extrusion can be done at room temperature to improve surface finish and strength, or at high temperatures (above 350 degrees Celsius) to reduce the amount of work hardening that occurs.

What are some applications for bespoke aluminum extrusions?

The following operations make up the entirety of the luminium extrusion process from beginning to end:

The heating process begins with an aluminum alloy billet. The temperature will typically range from 420 degrees Celsius to 500 degrees Celsius.

Lubricant is used to load the billet into the extrusion machine, which helps to reduce the amount of friction that occurs during the process.

The aluminum billet is pushed through the machine by a ram equipped with a high-pressure hydraulic system in order to reach the die.

An inert atmosphere is created by introducing nitrogen and allowing it to flow through the die sections in a continuous manner. This lengthens the amount of time the die can be used.


At this point, the extrusions go through any additional processing or finishing that may be necessary.

What are the benefits of having aluminum extrusions made specifically for your needs?

Complicated components with cross-sectional views

Production ranging from low to high volumes

Tune the mechanical performance to your liking.

It is possible to tailor the strength of aluminum extrusions by adjusting the wall thickness of the extrusion as well as the internal structural Aluminum Profile of the extrusion. Because of this, the strength can be concentrated exactly where it is required, without the addition of any unnecessary additional material.

Easily produced and inexpensive components

Extruding is a very effective method of production because Aluminum Profile allows for the continuous production of parts, which results in a significantly reduced cost per unit in comparison to other methods of production. Extrusion is a fantastic method for producing components on demand because, once the die has been created, it only takes a few days to go from raw material to finished product, which means it can be done very quickly.

Outstanding proportion of strength to weight

Extrusions made of aluminum are both lightweight (only one-third the weight of steel) and extremely strong in comparison to their weight. Because of this, they are a common option for applications in the aerospace industry, which places a premium on minimizing weight wherever possible.

What are some of the drawbacks associated with utilizing Custom Aluminum Extrusions?

Initial expenses associated with beginning a venture

There is an initial startup cost associated with the manufacturing of the extrusion die, although this cost is typically not very high. This cost, however, is quickly compensated for by the low cost of producing aluminum extrusions.

Architectural restraints

Because of how the extrusion process works, the cross-section of each component needs to be exactly the same. Additionally, there are a few other design considerations that need to be taken into account; these will be discussed in greater detail in the section that is dedicated to the design guidelines for custom aluminum extrusions.