How to Design and Order Custom Aluminum Extrusions for Your Application

Custom aluminum extrusions are a versatile and cost-effective solution for a wide range of industrial and commercial applications. Understanding how to design and order custom aluminum extrusions is crucial for businesses looking to optimize their product designs and manufacturing processes. This article provides a comprehensive guide to help you navigate the intricacies of custom aluminum extrusion design and ordering.

Design Considerations

1. Shape and Dimensions: Carefully consider the desired shape and dimensions of your extrusion. Determine the cross-sectional shape, length, and tolerances required for your specific application.

2. Material Selection: Choose the appropriate aluminum alloy based on the desired strength, corrosion resistance, and machinability characteristics. Common alloys include 6061, 6063, and 6082.

3. Wall Thickness: Specify the wall thickness and web thickness of your extrusion. These factors affect the strength and weight of the final product.

Manufacturing Process

1. Die Design: The first step in producing custom aluminum extrusions is creating a die that determines the shape of the extrusion. Collaborate with an experienced die maker to ensure the die meets your design specifications.

2. Extrusion Process: The aluminum alloy is heated and forced through the die under high pressure. This process creates the desired shape and dimensions of the extrusion.

3. Finishing Options: After extrusion, your extrusion can undergo various finishing processes such as anodizing, powder coating, or painting to enhance its appearance and durability.

Ordering Process

1. Supplier Selection: Research and select a reputable supplier with expertise in custom aluminum extrusion manufacturing. Consider factors such as experience, quality control, and lead times.

2. Drawing Submission: Provide the supplier with detailed drawings or 3D models of your desired extrusion. Ensure your drawings include all necessary dimensions, tolerances, and material specifications.

3. Sample Approval: The supplier may provide samples for your review and approval before proceeding with mass production.

4. Production Timeline: Establish a realistic production timeline with the supplier based on your order quantity and complexity.


Custom aluminum extrusions find applications in various industries, including:

1. Automotive: Structural components, trim, and body panels

2. Construction: Window and door frames, curtain walls, and roofing systems

3. Transportation: Railway cars, aircraft components, and marine structures

4. Electronics: Heat sinks, enclosures, and chassis

5. Medical: Surgical instruments, prosthetics, and medical equipment

By following the guidelines outlined in this article, you can effectively design and order custom aluminum extrusions that meet your unique application requirements. Custom aluminum extrusions offer a balance of strength, durability, and customization options, making them an ideal choice for a wide range of industries.

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