Precision Aluminum Extrusion Services
Aluminum Extrusion serves construction, transportation, and renewable energy industries. Common products:
- Window/door structural profiles
- Vehicle chassis rails
- Solar panel mounting systems
- Heat exchanger fins
- Conveyor track components
- Electronic heatsink channels
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Service
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Direct ExtrusionIdeal for solid profiles and simple cross-sections. Requires high force but offers cost-effective mass production of standard aluminum/copper extrusions. -
Indirect ExtrusionSuited for precision hollow profiles or thin-walled components. Lower friction reduces energy consumption, preferred for aerospace/automotive high-tolerance parts. -
Hot ExtrusionEnables large/complex shapes (e.g., structural beams) by heating metals above recrystallization temperature. Fast but requires post-processing for surface finish. -
Cold ExtrusionProduces high-strength, tight-tolerance parts (e.g., fasteners) at room temperature. Minimal finishing needed but limited to smaller, ductile materials.
Our Advanced Aluminum Extrusion Parts
Manufacturing custom profiles (6-300mm diameter) with 6000/7000 series alloys, our direct/indirect extrusion presses handle complex cross-sections and tight ±0.05mm tolerances. Offering anodizing, powder coating, and CNC machining integration for architectural, automotive, and heat sink applications.
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10+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
210+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
310+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest
Aluminum Extrusion Materials
Extruding 6000/7000 series alloys (6063-T5, 7075-T6) in complex profiles up to 300mm width. Anodizing and powder coating compatible for architectural, heat sink, and transportation applications with straightness tolerance of 1mm/m.
Metals
Lightweight, high thermal conductivity, Excellent Machinability, Superior Dimensional Stability, Tight-Tolerance Capable, Perfect for Complex CNC Milling and Turning.
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Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
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Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
Excellent balance of strength, corrosion resistance, and weldability; ideal for structural frames (e.g., window/door profiles, automotive chassis, and aerospace components). Offers good machinability and anodizing compatibility.
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Golden aesthetic, good machinability, moderate corrosion resistance, often used for decorative hardware.
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Superior wear resistance, seawater corrosion resistance, classic metallic luster, commonly cast.
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High thermal/electrical conductivity, antimicrobial surface, develops natural patina over time.
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High strength-to-weight ratio, magnetic properties, requires coating for rust prevention.
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Chromium-enhanced corrosion resistance, heat-resistant, maintains strength in extreme conditions.
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Extremely lightweight (67% aluminum density), good vibration damping, requires surface treatment.
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Aerospace-grade strength, biocompatible, seawater corrosion resistance, difficult to machine.
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Plastics
Fast-flowing melt, low shrinkage (0.4-0.7%), requires pre-drying (80°C/4h), ideal for automotive dashboards and consumer electronics housings.
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Extruded Aluminum Profiles Standard Dimensions
Note: These are general profiles commonly found in T-slot aluminum extrusions used for framing and other applications.
For specific industries or applications like windows, doors, or structural designs, the standard sizes may vary.
Aluminum Extrusion Surface Finishes
Looking for the right finish? Choose from 20+ options to meet both your functional and aesthetic needs.
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As MachinedDescription: Standard finish with surface roughness of 3.2 μm (126 μin), removes sharp edges and deburrs parts cleanly. Key Use: Functional parts requiring no post-processing (e.g., brackets, gears). Process Tolerance: Dimensional ±0.1 mm, Ra 3.2±0.5 μm Process Specifications: ISO 2768-m standard, burr height ≤0.05 mm
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AnodizingDescription: Electrochemical oxide layer for corrosion resistance and aesthetics. Process Compatibility: Post-machining surface treatment Key Use: Aerospace components, consumer electronics (e.g., phone frames). Process Tolerance: Coating thickness 10-25 μm±2 μm, color consistency ΔE≤1.5 Process Specifications: MIL-A-8625 or ISO 7599, sealing pH 5.5-6.5
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AlodineDescription: Chemical film for corrosion protection and paint adhesion. Process Compatibility: Post-cleaning chemical immersion Key Use: Aviation and automotive electrical housings. Process Tolerance: Film thickness 0.5-3 μm, visual uniformity Process Specifications: Immersion time 3-10 min, bath temp. 20-30℃
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Black OxideDescription: Thin magnetite layer for corrosion resistance and reduced glare. Process Compatibility: Post-machining chemical treatment Key Use: Tools, firearms, automotive fasteners. Process Tolerance: Coating thickness 0.5-1.5 μm, salt spray ≥24 hrs Process Specifications: Alkaline bath pH 13-14, process time 5-30 min
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BrushingDescription: Linear abrasive finish for decorative texture. Process Compatibility: Manual/CNC abrasive belts Key Use: Appliance panels, architectural trims. Process Tolerance: Texture depth 0.05-0.2 mm, angle deviation ≤5° Process Specifications: Abrasive belt grit 80-240, feed speed 10-30 m/min
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EtchingDescription: Chemical/mechanical removal for micro-texturing or marking. Process Compatibility: Laser/chemical masking Key Use: Circuit boards, decorative logos. Process Tolerance: Etch depth 0.01-0.5 mm±5%, alignment ±0.1 mm Process Specifications: Etchant concentration 10-30%, laser power 20-100 W
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Electroless PlatingDescription: Uniform metal coating (e.g., nickel) without electricity. Process Compatibility: Chemical bath deposition Key Use: Wear-resistant industrial valves, connectors. Process Tolerance: Coating thickness 5-50 μm±5%, porosity ≤5/cm² Process Specifications: Bath temp. 85-95℃, pH 4.5-5.5
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ElectroplatingDescription: Electrochemical metal coating (e.g., chrome, zinc) for durability. Process Compatibility: Post-machining electrodeposition Key Use: Automotive trim, jewelry. Process Tolerance: Coating thickness 5-25 μm±2 μm, adhesion ≥4B (ASTM B571) Process Specifications: Current density 1-10 A/dm², bath temp. 40-60℃
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ElectrophoreticDescription: Polymer coating via electric field for corrosion resistance. Process Compatibility: Post-cleaning immersion Key Use: Automotive frames, HVAC components. Process Tolerance: Coating thickness 15-30 μm±3 μm, edge coverage ≥80% Process Specifications: Voltage 50-300 V, cure 160-200℃×20 min
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GrindingDescription: Precision abrasive finish for tight tolerances. Process Compatibility: Surface/cylindrical grinding Key Use: Bearing races, hydraulic shafts. Process Tolerance: Dimensional ±0.005 mm, Ra 0.4-0.8 μm Process Specifications: Wheel grit 60-120, coolant flow 5-20 L/min
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Heat TreatmentDescription: Thermal process to alter material hardness/toughness. Process Compatibility: Post-machining quenching/tempering Key Use: Gears, cutting tools. Process Tolerance: Hardness HRC 45-60±2, distortion ≤0.1% Process Specifications: Quench temp. 800-1000℃, temper time 1-4 hrs
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KnurlingDescription: Diamond or linear pattern for improved grip. Process Compatibility: CNC lathe rolling Key Use: Handles, adjustment knobs. Process Tolerance: Pattern depth 0.2-0.5 mm, pitch ±0.05 mm Process Specifications: Roller pressure 200-500 N, feed 10-50 mm/min
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Laser EngravingDescription: Permanent marking via laser ablation. Process Compatibility: Post-processing laser systems Materials: Metals, plastics, wood Key Use: Serial numbers, branding on industrial parts.
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OvermoldingDescription: Molding soft material (TPU/silicone) over rigid inserts. Process Compatibility: Injection molding Materials: Plastics, metals (as inserts) Key Use: Ergonomic handles, waterproof seals. Process Tolerance: Overmold thickness 1-5 mm±0.2 mm, bond strength ≥5 MPa Process Specifications: Injection pressure >5 MPa, mold temp. 40-80℃
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PolishingDescription: Mirror-like finish via abrasive compounds. Process Compatibility: Manual/robotic buffing Key Use: Medical instruments, luxury fixtures. Process Tolerance: Ra 0.025-0.1 μm, gloss ≥90 GU Process Specifications: Wheel speed 1000-3000 rpm, compound grit 2000-5000
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PassivationDescription: Acid treatment to remove free iron and enhance corrosion resistance. Process Compatibility: Post-cleaning chemical immersion Key Use: Surgical tools, food processing equipment. Process Tolerance: Film thickness 0.001-0.01 μm, salt spray ≥96 hrs Process Specifications: Nitric acid 20-50%, process time 20-60 min
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Powder CoatingDescription: Electrostatic polymer powder cured into durable film. Process Compatibility: Post-cleaning spray and bake Key Use: Outdoor furniture, automotive wheels. Process Tolerance: Coating thickness 60-120 μm±10 μm, ΔE≤1.0 Process Specifications: Voltage 30-90 kV, cure 180-200℃×15 min
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PhosphatingDescription: Phosphate layer for lubrication and paint adhesion. Process Compatibility: Chemical immersion Key Use: Engine components, firearm parts. Process Tolerance: Coating weight 2-5 g/m², crystal size ≤5 μm Process Specifications: Bath pH 2-4, process temp. 40-70℃
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PaintingDescription: Liquid coating for color and protection. Process Compatibility: Spraying/dipping Materials: Metals, plastics Key Use: Consumer electronics, automotive body panels. Process Tolerance: Coating thickness 20-50 μm±5 μm, adhesion ≥3B (ASTM D3359) Process Specifications: Spray pressure 0.3-0.6 MPa, cure 80-120℃×30 min
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Sand blastingDescription: Abrasive jet finish for uniform matte texture. Process Compatibility: Post-machining blasting Materials: Metals, glass, stone Key Use: Architectural facades, engine blocks. Process Tolerance: Ra 1.6-6.3 μm, coverage ≥95% Process Specifications: Grit size 80-120, air pressure 0.4-0.7 MPa
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What is Aluminum Extrusion?How Does Aluminum Extrusion Work?
Aluminum Extrusion is a manufacturing process that shapes aluminum alloy into specific cross-sectional profiles by forcing heated material through a precision die. This method produces lightweight, strong, and corrosion-resistant components used in construction, automotive, aerospace, and consumer goods. Common examples include window frames, heat sinks, and structural beams.
Billet Preparation:Aluminum alloy billets (cylindrical blocks) are heated to 400–500°C to make them malleable for extrusion. Lubricants are applied to reduce friction during the process.
Die & Tooling Setup:A custom-designed steel die with the desired profile shape is mounted into the extrusion press.The press applies hydraulic or mechanical force to push the billet through the die opening.
Extrusion Process:The softened aluminum flows through the die, taking its shape while maintaining consistent cross-sectional dimensions. Quenching (rapid cooling) with air or water preserves mechanical properties and minimizes distortion.
Post-Processing:Extruded profiles are stretched to straighten and relieve internal stresses. Cutting, aging (heat treatment), and surface finishing (anodizing, powder coating) enhance strength and aesthetics.
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CNC MachiningWe specialize in manufacturing custom prototypes and end-use parts with precise and complex designs through CNC milling,CNC turning, and CNC precision machining. -
Sheet Metal FabricationWe expert in the flexible manufacture of sheet metal prototypes and precision parts through laser cutting, stamping, metal bending, metal welding, riveting, embossing, flanging and tapping, chamfering and other processes. -
Injection Molding ServicesWorldsoaring provides plastic injection molding, rapid and production tooling, overmolding, and insert molding service. No MOQ required, all while maintaining high-quality and precision molding products. -
More ServicesSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price. -
SolutionsSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price.
Success Stories of Aluminum Extrusion Projects
FAQs
How thick can an aluminum extrusion be?
Standard aluminum extrusions range from 0.5mm (0.02") precision thin-walls to 250mm (10") thick profiles. Maximum achievable thickness depends
on alloy properties (6061 permits thicker sections than 6063), press capacity (up to 10,000 tons), and die design capabilities. Industrial applications
typically utilize 1-50mm thicknesses for optimal structural performance.
Is extruded aluminum stronger than steel?
While steel exhibits higher absolute strength, extruded aluminum offers superior strength-to-weight ratios (approximately 1/3 steel's density). This,
combined with inherent corrosion resistance and thermal conductivity, makes aluminum extrusions preferable for weight-sensitive applications in
aerospace, automotive, and building systems. Material selection requires careful engineering analysis of structural requirements.
What is the most common aluminum extrusion?
The 6063 aluminum alloy dominates extrusion applications due to its exceptional extrudability, superior surface finish, and excellent anodizing response.
Its optimal mechanical properties make it ideal for architectural profiles and thin-walled components across construction and manufacturing sectors.
