Extruded Aluminum Profiles for Custom Shapes
We manufacture extruded aluminum profiles in solid, hollow, thin-wall and
complex cross-sectional shapes. Aluminum extrusions can be produced
to your drawing with custom tooling, CNC machining and surface finishing.
• 600–4000T Extrusion Presses
• Extruded Lengths up to 7 m
• CNC Machining up to 6.5 m
• 3-, 4- & 5-Axis CNC Machining
Aluminum Extrusion Profiles and Shapes
Aluminum extrusion profiles are available in standard and custom shapes for different product designs. Extruded aluminum shapes can include simple open sections, hollow sections, channels and more complex cross-sections with internal cavities, fins, grooves and other functional features.
Standard Aluminum Extrusion Shapes
Custom Aluminum Extrusion Profiles
Aluminum Extrusions by Product Type
Custom Aluminum Extrusion Profiles Examples
Custom aluminum extrusions can be produced according to your drawing, including solid, hollow and complex cross-sectional profiles. Features such as internal chambers, mounting grooves, screw channels, cooling fins and machining allowance can be incorporated into the extrusion design.
We support tooling, extrusion, CNC machining and surface finishing for custom aluminum profiles.
Standard and Structural Aluminum Extrusions
Aluminum extrusion profiles can be produced in standard and industrial cross-sectional designs, including channels, rails, solid sections and hollow sections.
Profile dimensions, wall thickness and section features can be adjusted according to the required structure, assembly and machining requirements.
Aluminum Extrusion Capabilities
| Capability | Range |
|---|---|
| Round Profile Diameter | Up to Ø400 mm |
| Wide Extrusion Width | Up to 450 mm |
| Extruded Length | Up to 7 m |
| CNC Machining Length | Up to 6.5 m |
| Extrusion Press | 600–4000T |
| Wall Thickness | Evaluated according to profile size and cross-section |
| Tolerances | Reviewed according to profile geometry and drawing requirements |
| Common Alloys | 6061-T6, 6063-T5 |
Available aluminum extrusion sizes depend on the profile geometry, alloy, wall thickness and cross-sectional design.
Aluminum Extrusion Services
Our aluminum extrusion services cover tooling, extrusion production, CNC machining, surface finishing and quality inspection for custom aluminum extrusion profiles. Each profile is reviewed according to its cross-section, dimensions, machining and finishing requirements before production.
- Extrusion Tooling
- Extrusion Production
- CNC Machining
- Surface Finishing
- Quality Control
Aluminum Extrusion Tooling Capabilities
Custom aluminum extrusion tooling is developed according to the profile drawing and cross-sectional design. Tooling requirements vary for solid, hollow, thin-wall, finned and other complex aluminum extrusion profiles.
- Custom tooling developed from customer drawings
- Solid, hollow, thin-wall and heat sink extrusion dies
- Trial extrusion and profile verification
- Die correction according to dimensional and filling results
- Die maintenance and modification for repeat production
Aluminum Extrusion Production
Aluminum extrusion profiles are produced on different extrusion presses according to profile size, cross-sectional geometry and alloy. After extrusion, profiles are cooled, stretched, straightened and cut according to the production requirements.
- 600–4000T extrusion presses
- 6061 and 6063 aluminum alloys
- Solid, hollow, thin-wall and finned extrusion profiles
- Large and complex aluminum extrusion profiles
- Extruded lengths up to 7 m, depending on profile size and cross-section
- Trial extrusion and volume production
- Cooling, stretching, straightening and cutting
- Press selection according to profile size and geometry
CNC Machining for Aluminum Extrusion Profiles
CNC machining can be completed after extrusion for holes, slots, openings, threads, mounting features and other drawing requirements. Long aluminum extrusion profiles can also be machined when the profile size and machining position are suitable.
- 3-, 4- and 5-axis CNC machining
- Long-profile machining up to 6.5 m, depending on the part
- Milling, drilling, tapping and slot machining
- End machining and cut-to-length processing
- Machining of mounting and assembly features
- Inspection according to drawing requirements
Surface Finishing for Aluminum Extrusion Profiles
Aluminum extrusion profiles can be supplied with anodizing, powder coating, sandblasting, brushing and other surface finishes according to appearance and application requirements.
- Clear, black and custom-color anodizing
- Hard anodizing for wear-resistant surfaces
- Powder coating and electrophoretic coating
- Sand blasting and brushing
- Custom colors according to project requirements
- Masking and contact-point confirmation
- Coating thickness and batch consistency inspection
Quality Control for Aluminum Extrusion Profiles
Aluminum extrusion profiles are inspected at different production stages, including trial extrusion, CNC machining, surface finishing and final inspection. Critical dimensions and features are checked against the drawing and approved requirements.
- Profile cross-section and overall dimensions
- Wall thickness, cavities, grooves and fin spacing
- Machined holes, openings and mounting features
- Flatness and straightness verification
- Anodizing and coating thickness measurement
- Thread, fastening and assembly verification
- Appearance and batch consistency inspection
- Inspection against drawings and approved samples
Inspection Stages: Trial Extrusion | CNC Machining | Surface Finishing | Final Inspection
Custom Aluminum Extrusion Design & Engineering Review
Before tooling, each custom aluminum extrusion is reviewed according to the drawing and final application. We check the profile cross-section, wall thickness, hollow sections, fins, mounting features, assembly interfaces and machining areas before die development.
For complex aluminum extrusion profiles and shapes, the review also considers metal flow, dimensional stability and secondary machining requirements. This helps identify potential manufacturing issues before trial extrusion.
Wall thickness is reviewed across the complete aluminum extrusion profile, especially where thin and thick sections are connected. Large thickness variations can affect metal flow, dimensional stability and the consistency of the extruded shape.
For hollow aluminum extrusion profiles, internal chambers, ribs, wall thickness and critical dimensions are reviewed together with the die structure. Complex hollow sections may require additional control during tooling and trial extrusion.
For heat sink and finned aluminum extrusions, fin thickness, fin height, spacing and base thickness are reviewed as a complete cross-section. The design needs to balance cooling requirements with extrusion feasibility.
A custom aluminum extrusion profile can integrate PCB guides, cover grooves, screw channels and other assembly features directly into the cross-section. These features are checked against mating components and final assembly requirements before tooling.
Mounting grooves, reference surfaces and other functional features can be incorporated into extruded aluminum profiles. Holes, slots and threads that require tighter control can be completed by CNC machining after extrusion.
For custom aluminum extrusions requiring secondary machining, additional material can be reserved around holes, openings, threads, sealing surfaces and mounting areas. Final machining requirements are considered during profile design rather than after the extrusion is produced.
Aluminum Alloys for Extrusion Profiles
6063 and 6061 are commonly used aluminum alloys for extrusion profiles. The alloy and temper are selected according to profile geometry, mechanical strength, CNC machining and surface finishing requirements.
| Alloy | Manufacturing Characteristics | Typical Applications |
|---|---|---|
| 6063-T5 | Good extrudability, surface quality, and anodizing performance | Complex hollow profiles, thin-wall profiles, heat sink profiles and enclosures |
| 6061-T6 | Higher mechanical strength and good machinability | Structural aluminum profiles, load-bearing parts and CNC-machined extrusions |
6063 Aluminum Billets for Extrusion
CNC Machining for Aluminum Extrusion Profiles
CNC machining is used after aluminum extrusion to complete features that cannot be formed directly in the profile cross-section. Mounting surfaces, connector openings, slots, holes, threads and end features can be machined according to the drawing. Fixtures, support points and machining datums are selected according to profile length, wall thickness and critical dimensions.
Flat reference and mounting surfaces on aluminum extrusion profiles can be machined where assembly contact, sealing or thermal contact requires controlled flatness.
Connector openings, ventilation slots, cable entries and assembly cutouts can be CNC machined after extrusion according to the required positions.
Mounting, fastening and positioning holes can be drilled in extruded aluminum profiles according to the specified locations and diameters.
Internal threads can be added to aluminum extrusion profiles for end plates, brackets, covers and component installation.
Machined edges, holes and openings are deburred or chamfered to remove sharp edges and prepare the profile for finishing and assembly.
Heat sink extrusion fins can be machined locally to control fin height, create component clearance or meet final dimensional requirements.
Surface Finishes for Aluminum Extrusion Profiles
Aluminum extrusion profiles can be supplied with sand blasting, brushing, anodizing, hard anodizing, powder coating, and wet painting. The finish is selected according to surface appearance, corrosion resistance, wear resistance, color requirements, and the final application.
Sand blasting creates a uniform matte texture on aluminum extrusion profiles and helps reduce visible extrusion or machining lines before anodizing.
Brushing produces a directional surface texture for visible aluminum profiles and can be combined with anodizing where a decorative finish is required.
Black anodizing provides corrosion resistance and a black finish for aluminum extrusion profiles used in electronic enclosures, heat sinks, and industrial components.
Hard anodizing is available for extruded aluminum components where increased surface hardness and wear resistance are required.
Powder coating provides color, surface protection, and additional corrosion resistance for aluminum extrusion profiles.
Wet painting is available for aluminum profiles requiring custom colors, specific coating systems, or controlled surface appearance.
Anodized appearance depends on alloy, extrusion surface condition, pretreatment, and production batch. Visible surfaces and color requirements are confirmed before finishing.
Industrial Applications for Aluminum Extrusion Profiles
Custom aluminum extrusion profiles are used when enclosure protection, heat dissipation, mounting, and structural support need to be integrated into one component. Profile geometry, CNC machining, and surface finishing are configured according to equipment layout, interface positions, cooling requirements, and operating conditions.
Profile development starts with the internal layout, heat source, connector positions, and mounting method—not only the external dimensions.
Extruded housings can integrate cooling fins, PCB guides, connector openings, and mounting features for network and communication equipment.
Profiles provide enclosure structures, internal mounting space, and machined interfaces for industrial controllers and automation equipment.
Heat-dissipating enclosure profiles combine component mounting surfaces, external fins, and protective housing structures.
Extruded housings can include internal guide rails, end-plate interfaces, and machined openings for displays, controls, and connectors.
Profiles can integrate PCB or module mounting, connector interfaces, cooling structures, and protective enclosure features.
Profiles combine structural support, driver space, mounting features, and heat dissipation for indoor and outdoor lighting equipment.
Discuss Your Aluminum Extrusion Project
Send us your drawing, sample photo, profile dimensions, or application requirements. Glary will review your project and recommend the next step.
