What Is Custom Aluminum Extrusions?
Custom aluminum extrusion profiles are versatile and essential components used in various industries.
These profiles are created through a precise manufacturing process that involves shaping aluminum into specific cross-sectional shapes.
With their lightweight nature and excellent strength-to-weight ratio, custom aluminum extrusion profiles offer numerous advantages.
The amount of customization that goes into the finished part, piece or product depends on the specific needs of the client.
While many extrusion shops promise to create custom aluminum products, they can be limited by what they are able to produce.
However, large shops that have been in the business for many years and have built a reputation for creating truly custom aluminum extrusion, have the full capability of creating a finished result that is one-hundred percent custom, original and according to the client’s specifications.
Step By Step Guide To Manufacturing Aluminum Extrusion Profiles
Aluminum extrusion is a versatile and widely used process for creating intricate profiles used in various industries. Follow these steps to manufacture aluminum extrusion profiles:
#1. Aluminum Alloy Selection.
Aluminum alloy selection is the vital first step in crafting precise extrusion profiles. Choosing the right alloy dictates the profile’s strength, corrosion resistance, and other characteristics.
This decision forms the foundation for a successful extrusion process, ensuring the final product meets design requirements and performance expectations.
#2. Custom Extrusion Design And Die Preparation.
Begin by designing the desired shape and dimensions of the aluminum extrusion profile using specialized software.
Once the design is finalized, create a die, which is a tool that shapes the aluminum under pressure. The die should match the profile’s specifications and intricacies.
#3. Billet Heating.
Load an aluminum billet, a cylindrical piece of aluminum, into a furnace and heat it to the required temperature. Heating makes the aluminum malleable and ready for extrusion.
#4. Extrusion Tooling Process.
The heated billet is pushed through the die using a hydraulic press. The pressure forces the aluminum to take on the shape of the die’s opening. As the aluminum passes through, it forms the desired profile.
#5. Cooling And Cutting.
After extrusion, the newly shaped aluminum profile is rapidly cooled using water or air to maintain its structural integrity. Once cooled, the continuous extrusion is cut into desired lengths using a saw or other cutting tools.
#6. Straightening And Quality Check.
The extruded profiles may undergo a straightening process to correct any distortions caused during extrusion.
Finally, conduct a quality check to ensure that the dimensions, surface finish, and overall quality meet the required standards.
#7. Packaging And Distribution.
Approved profiles are packaged securely to prevent damage during transportation. They are then distributed to manufacturers for use in various applications.
Why To Choose Aluminium To Create Custom Extrusion Products?
Compared to other materials, there are many benefits associated with choosing aluminum. The ability to create standard extrusions and custom aluminum extrusion is just one of many reasons why manufacturers choose to create custom aluminum products.
Aluminum fabrication shops are able to use recycled aluminum materials, which makes these products very beneficial to the environment.
They can be recycled again and again, over and over for an unlimited number of times.
This makes aluminum products very cost-effective compared to other materials and its simultaneous malleability and strength allows it to be shaped and used for many different applications and industries.
Aluminum is easy to work with in custom or standard extrusions, allowing for the creation of simple or complex shapes and cross-sections, even when non-uniform thickness is required.
Extrusion allows the shape to be completed in one single process, negating the need for welding or joining, which can increase manufacturing costs and create a less-durable end product.
Additional options can be included in the custom aluminum extrusion die design, such as self-tapping features, snap or sliding fit, press fit and even tongue and groove to allow for simple and sturdy assembly.
What Are The Finishing Option For Custom Aluminum Extrusions?
Listed below are the various finishing options available for aluminum extrusions:
- Basic Mechanical Finishing
- Anodization
- Painting
- Powder Coating
- Silk-Screen Printing
- Laser Engraving
#1. Basic Mechanical Finishing.
Basic mechanical finishing that can include standard part cleaning and deburring. The part is cleaned to remove any oil or grease introduced during manufacturing and any burrs are removed. Extruded profiles will have a surface roughness between 64 µin and 125 µin Ra.
#2. Anodization.
One of the primary methods of increasing the wear and corrosion resistance of aluminum is through anodizing.
The anodizing process converts the surface of the aluminum into a scratch- and chemical-resistant coating of aluminum oxide.
Type II anodizing produces a coating with a thickness of between 0.0002″ and 0.0012″ that can also be dyed in various colors.
Type III anodizing, also called hard coat anodizing, is better suited to applications that require increased wear resistance.
Type III coatings typically have a thickness of 0.002″. Type III coatings are not commonly dyed and have a dark appearance but can be painted. It must be noted that anodized dye colors cannot be matched to specific Pantone or RAL color codes.
#3. Painting.
Aluminum extrusions can be painted using either spray coatings or manually applied water- or solvent-based paints.
Paint colors can be matched to specific Pantone or RAL color codes. The paint provides a continuous and protective finish.
#4. Powder Coating.
Aluminum extrusions can be powder-coated to provide a tough, corrosion-resistant coating that holds its color well when exposed to harsh outdoor environments.
Powder coating is essentially a thermoplastic or thermoset powder that is applied using an electrostatic effect.
The coating is baked or cured onto the extrusion surface creating a continuous durable coating with a thickness of between 0.006″ and 0.012″.
Various colors are available. Coatings can be applied in accordance with ASTM D7803 as well as applicable MIL and FDE specifications.
#5. Silk-Screen Printing.
Silk-screen printing is mainly used to apply markings or images onto the surface of the aluminum extrusion.
This process works by using a mesh, typically nylon or polyester, to transfer ink onto a stencil. This ensures that only the desired image or text is transferred to the extrusion; thereafter, it is cured using a UV light.
These markings can be used for company branding, or for production traceability purposes. The coating is highly durable and does not peel off.
#6. Laser Engraving.
Laser engraving provides a more permanent method of marking an aluminum extrusion. It works by tracing a laser beam in the desired shape and melting the surface of the aluminum.
This melting creates a contrast between the standard surface finish of the extrusion and allows for permanent traceability for quality purposes or company branding.
Advantages of Custom Aluminum Extrusions
#1. Consistency.
Aluminum extrusions have a consistent cross-section as the part will pass through the same die during production.
After extrusion, the part is also straightened to ensure it is consistent along its entire length and meets dimensional requirements.
#2. Fast Manufacturing.
Once the die is manufactured, the actual extrusion process is extremely quick. Some aluminum parts are suitable for feed rates from 2 to 20 ft/min.
Fast manufacturing means reduced lead times and lower cost per meter of extruded aluminum. It must however be noted that the extrusion die can take several weeks to design and manufacture.
#3. Reduced Material Waste.
Only the required material is used in the extrusion and there is minimal wastage. For example, if the part were to be manufactured using CNC machining, there would be a lot of waste as the cross section would need to be produced by removing material.
#4. Lightweight.
Extrusion designs can be optimized for low weight while still maintaining the required stiffness. Complex cross sections can be designed such that the specified load cases are optimized. Lightweight designs mean reduced raw material costs.
#5. Cost Effective.
The cost-effectiveness of aluminum extrusions is due to a number of factors. The speed with which aluminum extrusions are manufactured means a lower cost per part.
In addition, there is very little raw material wastage and extrusions can be designed to be extremely lightweight without sacrificing their performance.
#6. Heat Conductive.
Aluminum is heat conductive. This can be very useful for heat exchangers or heat sinks. Custom heat sink profiles can be produced to optimize heat transfer without having to resort to complex manufacturing processes like CNC machining.
#7. Corrosion-Resistant.
Uncoated aluminum can be highly corrosion-resistant due to the natural oxide that forms on the surface over time.
This oxide can be artificially reproduced using anodizing to create highly corrosion-resistant surfaces.
Aluminum extrusions can also be coated using a variety of techniques like powder coating or painting to further improve their corrosion resistance.
#8. Versatility in Design.
Specific aluminum extrusions offer more flexibility in terms of design since they can accommodate such things as curves, angles, and other geometrical forms that are difficult to achieve with other extrusion methods.
This simplicity makes it possible to guarantee that any project implemented receives an efficient solution meeting its functional needs while at the same time being visually appealing.
#9. Efficiency in Production.
These companies eventually cut manufacturing costs by using custom extrusions in their business operations.
This way a single process cuts and shapes the material with high precision resulting in the elimination of subsequent processes and cutting down costs.
#10. Material Strength and Durability.
Aluminum has a high strength-to-weight ratio, and the application of custom extrusions provides a way of improving the material distribution.
This results in components that do not only offer strength but also endurance hence not easily degraded by environmental factors or often usage.
Disadvantages of Custom Aluminum Extrusions
#1. Prone To Wear.
The die used to create the cross-section of the extrusion is exposed to a constant flow of aluminum at high pressure.
This can cause wear on the die that may require periodic replacements during high-volume manufacture.
In addition, untreated aluminum extrusions will have less wear resistance than steel (a harder material). This can however be improved with hard coat anodizing.
#2. Low Production Efficiency.
It is not possible to have continuous production as a new billet needs to be added regularly due to the nature of the extrusion process, i.e, the need to force a limited-size aluminum billet through a die.
As such, the overall production efficiency of aluminum can be low if smaller volumes are produced.
#3. High Upfront Cost.
Choosing custom aluminum extrusions can be more costly than using a standard off-the-shelf extrusion. This is because it can be expensive to design and manufacture a custom die.
In addition, a large initial order quantity may need to be manufactured to justify the initial setup cost.
Despite this, custom aluminum extrusion is an excellent option if a specific profile is required that cannot be purchased off the shelf.
#4. Uneven Tissue Performance Of Products.
Because the flow of metal is not uniform during extrusion (especially serious when there is no lubricating forward extrusion), the surface layer, center, head and tail of the extrusion products are not uniform.
#5. The Working Conditions Of The Extrusion Die Are Harsh And Easy To Worn Out.
During extrusion, the blank is in a nearly closed state with high three-way pressure. At the same time, the mold is usually subjected to high temperature and high friction during hot extrusion, which greatly affects the strength and service life of the mold.
Applications of Custom Aluminum Extrusions
Aluminum extrusions come with an impressive combination of properties that make them ideal for a wide range of applications.
We’ve created a list of popular examples from four of the biggest industry sectors to give you an idea of all the places you can already find aluminum extrusions.
#1. Construction and architecture.
The building and construction industry currently utilizes the largest share of extruded aluminum products, and for good reason.
Architectural elements like large engineered skylights and canopies need strong, but lightweight structural members.
Roofing, fencing, and pretty much anything exposed to the outdoors needs to have excellent corrosion resistance, and may need additional finishing options like anodizing.
And the assembly of prefabricated components on a work site needs to be fast, visually appealing, and sometimes even adjustable.
All of these needs in a variety of shapes can be met with well-designed aluminum extrusions at a reasonable cost.
This is why aluminum extrusions are a great choice for creating stunning and durable structures in the construction and architecture sector.
#2. Automotive And Transportation.
One of the biggest factors driving automotive makers towards aluminum products is reducing vehicle weights to help improve efficiency.
Vehicle cross members, subframes, trim, and accessories can all be made efficiently from extruded aluminum to lower weight while maintaining strength.
This is the same reason for choosing aluminum extrusions for a growing number of components on buses, utility trailers, off road vehicles, and even aircraft.
The corrosion resistance of aluminum is useful for improving the durability of any transport exposed to the outdoors but is especially useful in marine environments, including boats and docks.
Aluminum extrusions can even be used to make lightweight battery boxes for electric vehicles (EVs) that help regulate battery temperature.
#3. Electrical And Electronics.
Aside from beautiful finishes on consumer electronics and appliances, extruded aluminum can be easily formed to make electrical enclosures and cases.
Its main value to the electrical and electronics sector though comes from its high thermal and electrical conductivity at a much lower cost and weight than copper.
Aluminum extrusion is a popular method for making heat sinks that keep electronics from overheating, and aluminum wires are common for both high-voltage transmission lines and smaller-scale wiring.
#4. Consumer Products.
While consumer products make up a smaller market than the other listed areas, aluminum extrusions are still a popular choice in this sector.
Consumer products can cover a wide range of applications, so aluminum extrusions are typically chosen for their unique combination of properties while maintaining a low cost to produce.
Camping chairs, baseball bats, golf clubs, bicycles, cookware, furniture pieces, beverage cans, and much more are commonly made from extruded aluminum.
Alternatives to Custom Aluminum Extrusions
1. CNC Machining: CNC machining is ideal for low-volume highly custom profiles when producing a custom aluminum extrusion is too costly and time-consuming.
2. Laser Cutting & Sheet Metal Bending: Sheet metal bending can be used to produce simple profiles that can have various features laser cut prior to bending.