Custom Profiles, Heat Sinks,
Housings
We machine custom aluminum extrusion profiles, extruded
aluminum heat sinks and housings according to your drawing,
including flat mounting surfaces, holes, threads, slots and
other assembly features.
From Extruded Profile to Finished Component
Each part starts as an extrusion designed for its main cross-section. CNC machining is then used only where functional mounting, connection or assembly features are required.
Machining Features on Extruded Aluminum Parts
Face milling creates a flat mounting or thermal contact surface where required. It can be applied to the top, base or other specified areas of the profile.
Slots and local machined areas are used for connectors, covers, brackets and other assembly interfaces.
Drilled holes are added for screws, brackets, PCBs and end covers. Positions are machined after cutting to the required length.
Threaded holes provide fixing points directly in the extrusion, without separate inserts where sufficient material is available. Thread size, depth and position are confirmed from the drawing.
Countersinks and screw recesses allow fastener heads to sit flush where required. Their dimensions are machined according to the screw type and assembly requirement.
Local machining can be carried out close to finned sections where required.
CNC Planning Starts Before Extrusion
CNC machining is considered together with the extrusion profile, not added after the profile design has been completed.
Before tooling, we review:
- Profile section and wall support
- Machining datums and clamping areas
- Tool access and machining direction
- Critical hole positions and flat surfaces
- Finished length and production quantity
This helps avoid profile features that are difficult to hold, unsupported walls around machined openings or internal areas that cannot be reached by the cutting tool. For repeat production, the extrusion section and machining sequence are planned together so that the same reference surfaces can be used throughout production.
Workholding and Reference Surfaces
Extruded aluminum parts often have thin walls, fins, open channels or uneven sections. These features can make direct clamping difficult and may lead to deformation or surface marks if the workholding is not planned correctly.
Fixtures are selected according to the profile section, finished length and machining direction. Where required, dedicated support areas are used to hold the part during drilling, tapping, milling or slot machining. The machining datum is confirmed before production so that hole positions, mounting faces and assembly features are controlled from the correct reference. This is especially important for heat sinks, hollow housings and long profiles with repeated mounting features.
Tool Access for Hollow and Finned Profiles
Tool access is reviewed during drawing review, before machining begins. For hollow aluminum extrusions, the machining tool may need to enter from one or both open ends. Internal steps, deep pockets and recessed features are checked against the available tool diameter and reach.
For finned profiles, machining close to the fins requires sufficient clearance for the cutter and fixture. The machining method is selected to avoid bending, crushing or marking the fin structure. If a requested feature cannot be reached reliably, this is clarified during drawing review rather than after tooling or production has started.
Typical Manufacturing Sequence
The production sequence depends on the part design, but commonly includes:
- Trial extrusion and profile confirmation
- Cutting to required length
- Fixture setup and first-piece machining
- Face milling, drilling, tapping, slots or machined openings
- Deburring and dimensional confirmation
- Surface finishing, where required
- Final inspection and packing
For anodized or powder-coated components, the machining and finishing sequence is confirmed according to which surfaces must remain exposed, coated or free from contact marks.
Inspection After CNC Machining
Inspection points are defined from the drawing and the assembly function of the part. Depending on the component, these may include finished length, hole location, thread size, mounting-face condition, slot dimensions, machined opening position and flatness of specified surfaces.
First-piece inspection is completed before batch machining begins. During production, critical machined features are checked against the approved drawing and sample requirements.
Suitable Parts for CNC Machined Aluminum Extrusions
This manufacturing route is suitable when extrusion can form the main cross-section of the component, while CNC machining adds the final functional features.
Typical parts include:
- heat sinks with threaded mounting holes or machined contact faces
- electronic housings with connector openings, slots and end features
- industrial profiles with drilled hole patterns and assembly interfaces
- long extrusions with repeated machining positions
- hollow profiles requiring end machining or internal access from open ends
Examples of Finished Components
