Custom Profiles
Aluminum Extrusion Service
Develop custom linear profiles and complete them with cutting, machining, forming, finishing, hardware, and assembly.
- Profiles
- Solid, semi-hollow, hollow, heat-sink, structural, and custom forms
- Fabrication
- Sawing, drilling, milling, punching, tapping, bending
- Finishes
- Mill, anodized, powder coated, brushed, polished
Applications
Efficient geometry repeated along a length
Structural Profiles
Frames, rails, machine structures, supports, and modular systems.
Thermal Profiles
Heat sinks and housings with integrated fins and mounting features.
Enclosures and Trim
Electronic housings, channels, covers, tracks, and appearance components.
Fabricated Extrusions
Cut, machine, drill, tap, finish, mark, and assemble profiles into end-use parts.
Workflow
Custom extrusion program stages
Profile DFM
Review wall balance, hollows, tongues, radii, symmetry, tolerances, and alloy.
Die and Trial
Build the extrusion die, trial the profile, and correct flow or dimensional issues.
Extrude and Temper
Run billet, cool, stretch, age, inspect, and prepare stock for fabrication.
Complete Parts
Cut, machine, form, finish, inspect, package, and deliver production lots.
Alloys
Common extrusion alloy families
| Family | Common Uses | Selection Factors |
|---|---|---|
| 6063 | Architectural, trim, enclosure, and appearance profiles | Surface quality, formability, anodizing, moderate strength |
| 6061 | Structural and machined profiles | Strength, machining, availability, section complexity |
| 6005 / 6005A | Structural shapes and transportation-style components | Strength, weldability, profile design, temper |
| Specialty Alloys | Higher strength, conductivity, or application-specific needs | Extrudability, minimum run, tooling, heat treatment, supply |
Design Guidance
Help metal flow evenly through the die
Balance Wall Thickness
Uniform sections and gradual transitions improve flow, cooling, and dimensional stability.
Use Generous Radii
Rounded transitions strengthen the die and improve metal flow.
Identify Critical Dimensions
Do not over-tolerance the full profile; focus controls on functional interfaces.
Plan Fabrication Datums
Choose reference surfaces for cut length, machining, holes, assembly, and inspection.
FAQ
Extrusion questions
Can you machine and anodize extrusions?
Yes. Include cut length, machined features, finish type, color, cosmetic faces, masking, and packaging requirements.
Do custom profiles require tooling?
Yes. A custom die is developed for the cross-section, then trialed before production.
What volume information should I provide?
Share initial quantity, annual piece count or weight, cut lengths, program life, and expected release schedule.
Develop a Custom Profile