Custom Aluminum Extrusions
custom aluminum extrusions
Aluminium Extrusion Services
Aluminium Extrusion Services for Custom and Standard Profiles
SR is a manufacturing broker for aluminium extrusion. We collect quotes from a vetted supplier network, manage DFM review, quality and inspection, and deliver finished profiles to your specification.
- Custom profiles
- Standard extrusions
- 6063 / 6061 / 6082
- DFM review included
Quick answer
Aluminium extrusion is a process in which a heated aluminium billet is forced through a shaped die to produce a continuous profile with a fixed cross-section. SR brokers custom and standard aluminum extrusions, collecting quotes from vetted suppliers, reviewing designs for manufacturability, and managing inspection and delivery.
Aluminium Extrusion Capabilities: What the Service Covers
SR covers the full aluminium extrusion supply chain as a broker: profile design support, die sourcing, extrusion, heat treatment, finishing, cutting, machining and fabrication. We do not own factories or machines. We collect quotes from a vetted supplier network, compare them, and manage the order through to delivery.
Sub-processes we coordinate
- Direct extrusion: a billet is heated and pushed through a stationary die by a ram. Broad alloy and profile capability; suitable for solid and hollow sections.
- Indirect extrusion: the die moves through a relatively stationary billet. Lower friction and improved dimensional consistency for suitable profiles.
- Hot extrusion: billet temperature is raised enough to reduce flow stress before extrusion. The most common route; enables complex profiles and production rates.
- Cold extrusion: aluminium is formed below its hot-working temperature. Good surface finish and dimensional accuracy for smaller sections.
- Impact extrusion: a slug is rapidly forced around or through a punch to form a short hollow part. Efficient for seamless cups, cans and small housings.
Part size and volume range
Extrusions range from small solid sections to large hollow profiles. Profile size, wall thickness and volume are limited by the press, die and alloy selected. Typical production runs span prototype quantities through high-volume annual programs. Share your drawing and annual usage so suppliers can confirm feasibility.
Solid, semi-hollow, hollow
Profile types
Standard or custom cross-sections
Cutting, machining, fabrication
Secondary operations
Sawing, drilling, tapping, milling, punching, bending
5-7 working days
Quote turnaround
After a complete RFQ is received
Materials and Finishes for Aluminium Extrusion Profiles
Aluminium extrusion profiles are made mainly from 6000-series alloys, and the alloy and temper set strength, extrudability, surface finish and corrosion resistance. 6063 is the common choice for architectural and general-purpose profiles; 6061 and 6082 are selected when higher strength is required. Finishes are applied after extrusion and heat treatment.
| Alloy | Grade / temper | Properties | Typical uses |
|---|---|---|---|
| 6063 | 6063-T5 or 6063-T6 | Excellent extrudability, surface finish, corrosion resistance and moderate strength. Exact properties depend on temper and product form. | Architectural frames, trim, furniture, lighting, heat sinks and general-purpose profiles. |
| 6061 | 6061-T6 | Higher strength and good corrosion resistance, with lower extrudability and finish quality than 6063. | Structural frames, machine components, transport parts, brackets and machined extrusions. |
| 6005A | 6005A-T5 or 6005A-T6 | Intermediate-to-high strength with useful extrudability for structural sections. | Transport structures, platforms, ladders, frames and load-bearing profiles. |
| 6082 | 6082-T6 | High strength among common 6000-series extrusion alloys; generally less suited to very complex thin-wall shapes. | Structural, automotive, marine, transport and heavy-duty machined profiles. |
| 6005 | 6005-T5 | Good strength and extrudability for medium-duty structural applications. | Frames, rails, ladders and structural extrusions. |
Common finishes
- Mill finish: as-extruded surface, suitable when appearance is not critical.
- Anodizing: an electrolytic oxide layer for corrosion resistance and color; thickness and color must be specified.
- Powder coating: a cured polymer coating for durable color and exterior exposure.
- Painting and lacquering: liquid coatings for specific color or gloss requirements.
- Mechanical finishing: brushing, polishing or blasting for a defined surface texture.
For standard or custom aluminum profiles, specify alloy, temper, finish, color and coating thickness on the drawing. Finish choice affects corrosion performance, appearance and cost, and should be agreed before extrusion.
Aluminium Extrusion Tolerances and Lead Times
Tolerances depend on the applicable standard, alloy, temper, section and dimension. The values below are typical rules of thumb from European Aluminium guidance and should be confirmed against EN 755, EN 12020 or ASTM B221 for your profile. Lead times are typical and vary with die availability, alloy, finishing and quantity.
| Parameter | Typical range | Standard or source |
|---|---|---|
| Linear dimensions | Often approximately ±1% as a rule of thumb; actual limits vary by dimension, alloy, temper, section and standard. | European Aluminium, Extruded Products |
| Wall thickness | Often approximately ±5-10% as a rule of thumb; thinner walls generally require greater percentage allowance. | European Aluminium, Extruded Products |
| Angular geometry | Approximately ±2 degrees as a general rule of thumb. | European Aluminium, Extruded Products |
| Straightness, flatness, twist, corner radii | Profile- and size-dependent; specify acceptance limits using the applicable product standard. | EN 755-3 through EN 755-9; EN 12020 |
| Profile length | Cut-length tolerance is supplier- and order-specific; do not assume a universal value. | Applicable purchase specification and supplier drawing |
| Outside dimensions | Unverified: approximately ±0.006-0.020 in [±0.15-0.50 mm] is reported by a non-standards source. | Unverified secondary technical source; confirm against EN 755 or ASTM B221 |
Lead time factors
- Die manufacture for custom profiles adds time before extrusion begins.
- Standard profiles using existing dies generally shorten the front end.
- Alloy and temper availability affects scheduling.
- Finishing operations such as anodizing or powder coating add separate process time.
- Inspection and documentation requirements can extend the release timeline.
SR returns supplier quotes in 5-7 working days after a complete RFQ. Production lead time is confirmed per order and depends on the supplier, die status, finishing and quantity.
Industries and Applications for Extruded Aluminum Profiles
Extruded aluminum profiles are used wherever a constant cross-section, light weight and corrosion resistance matter. The table below lists common applications by industry with example parts.
| Industry | Example parts | Typical alloy |
|---|---|---|
| Automotive and transport | Structural frames, battery enclosures, roof rails, brackets, platforms | 6061-T6, 6082-T6, 6005A-T6 |
| Architecture and construction | Window and door frames, curtain wall mullions, trim, handrails | 6063-T5, 6063-T6 |
| Industrial equipment | Machine guards, conveyor rails, workstations, T-slot framing | 6063-T5, 6061-T6 |
| Electronics and lighting | Heat sinks, LED housings, enclosures, mounting rails | 6063-T5, 6061-T6 |
| Furniture and interiors | Desk frames, shelving, partitions, decorative trim | 6063-T5, 6063-T6 |
| Energy and infrastructure | Solar mounting rails, cable trays, support structures | 6063-T6, 6005A-T6, 6082-T6 |
Automotive buyers often require PPAP documentation and IATF 16949-aligned supplier quality systems. SR coordinates these requirements with the selected supplier and confirms capability before quoting.
How Ordering Aluminium Extrusions Works
Ordering aluminium extrusions through SR follows six managed steps, from RFQ to delivery. Each step is designed so you receive comparable quotes and a documented quality record.
- 1. Submit your RFQ Send the profile drawing or CAD, alloy, temper, finish, cut length, tolerances, annual and release quantities, packaging, inspection requirements, delivery location and applicable standard.
- 2. DFM review SR reviews the design for manufacturability: wall thickness, hollow versus solid section, die feasibility for custom aluminum profiles, alloy choice and secondary operations. We flag risks before quoting.
- 3. Vetted supplier quotes SR collects quotes from each aluminum extruder in its vetted network and typically returns them in about 5-7 working days. Quotes are compared on unit cost, tooling, lead time and quality capability.
- 4. Order placement You confirm the supplier and specification. SR places the order, confirms the die or standard profile route, and tracks the production schedule.
- 5. Quality control Inspection is performed against the drawing and applicable standard. First article, dimensional checks and documentation are completed before release.
- 6. Shipping and delivery Profiles are packed to the agreed specification and shipped to your delivery location. SR coordinates freight and documentation.
A complete RFQ shortens quote turnaround. Missing alloy, temper, finish or tolerance data is the most common cause of delay.
Quality and Inspection for Aluminum Extrusions
Quality control is applied at the supplier and verified by SR before shipment. Inspection scope is agreed at order placement and matched to the drawing, standard and end use.
- Dimensional inspection: cross-section, wall thickness, length and angular geometry against the drawing.
- Form checks: straightness, flatness and twist per the applicable standard.
- Surface inspection: finish quality, coating thickness and visual defects.
- First article inspection: full dimensional report on the first production piece.
- Material verification: alloy and temper confirmed by supplier certificate.
- Traceability: heat or lot identification linked to the production record.
- Documentation: inspection reports and certificates supplied with the shipment.
Standards used for extrusion quality
- ASTM B221 (inch-pound and metric editions): extruded bars, rods, wires, profiles and tubes.
- EN 755: technical conditions, dimensions, tolerances and testing for hot-extruded products.
- EN 12020: tighter dimensional and form requirements for precision profiles.
- ASTM B241 (inch-pound and metric editions): seamless pipe and seamless extruded tube.
- Aluminum Association alloy and temper designations: the recognized designation system for purchase specifications.
What Drives the Cost of Aluminium Extrusion
Extrusion cost is driven by material, tooling, process time and logistics. No universal price is reliable without a specification. The factors below explain where cost comes from and how to reduce it.
Cost drivers
- Profile weight per foot [per metre] and material yield.
- Alloy and temper selection.
- Die cost and complexity for custom profiles.
- Wall thickness and section complexity.
- Finishing type and coating thickness.
- Packaging, freight, inspection, tooling ownership and lead time.
How to reduce cost
- Use a standard profile when the design allows.
- Optimize wall thickness to the minimum that meets strength and tolerance needs.
- Select 6063 where high strength is not required.
- Combine features into one profile to reduce assembly.
- Match finish to the actual exposure and appearance requirement.
- Confirm quantities and release schedules early to improve supplier planning.
Supplier-published estimates report approximately $2.50-$8.00 per kilogram [$1.13-$3.63 per pound] and die costs of $400-$3,000+. These figures are unverified supplier estimates, not standards-based values, and should not replace quotations.
Have a drawing to quote?
Upload it with quantity and material to start a quote.
FAQ
Common questions
What information should an RFQ for custom aluminium extrusions include?
A complete RFQ should include the profile drawing or CAD, alloy, temper, finish, cut length, tolerances, annual and release quantities, packaging, inspection requirements, delivery location and applicable standard. Complete data lets suppliers quote on the same basis and shortens turnaround.
Are standard aluminum extrusion profiles cheaper than custom profiles?
Usually, yes. A standard aluminum extrusion profile uses an existing die, which avoids new tooling cost and typically shortens lead time. Unit cost still depends on alloy, weight, quantity, finish, cutting, machining and freight, so compare quotes for both routes.
What is the difference between aluminium and aluminum extrusion?
There is no technical difference. Both terms describe the same process and material: forcing a heated billet through a shaped die. Aluminium is the common spelling internationally, while aluminum is the usual spelling in United States usage.
Can aluminium extrusions be machined?
Yes. Aluminium extrusions are commonly machined after extrusion. Typical secondary operations include sawing, drilling, tapping, milling, punching, bending and assembly. Agree machining allowances and distortion controls with the supplier before production starts, because they affect final tolerances.
Related resources
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Ready to quote your aluminium extrusion project?
Send your profile drawing, alloy, temper, finish and quantities. SR returns vetted supplier quotes in 5-7 working days and manages inspection through delivery.
Your files stay confidential. NDA available on request.