The Ultimate Guide to Aluminium Extrusions

From copper, steel and brass to thermoplastics and ceramics, extruded materials are used and sourced by businesses throughout countless industries across the world.

Few material extrusions are as widely used or as versatile as extruded aluminium, however, which serves as a lightweight, high strength, and cost-effective staple for product manufacturing and design. But what exactly are aluminium extrusions, and how can businesses like yours maximise the value of your extruded aluminium profiles?

At Edmo, we have over 45 years of experience as a full service, high volume aluminium extrusion service provider based in the UK. In this guide we cover everything from the basics of aluminium extrusion processes to key terminology, manufacturing processes, limitations, and design considerations for businesses like yours sourcing aluminium extrusion engineering services. For more information and service enquiries, contact our experts for technical support and to receive a free, no obligation quote.

For more information and service enquiries, contact our experts for technical support and to receive a free, no obligation quote.

Quick content guide:

• What is aluminium extrusion?
• Why are aluminium extrusions used?
• How are aluminium extrusions made?
• What makes aluminium extrusions so versatile?
• What products are made from aluminium extrusion?
• What types of aluminium extrusion can be made?
• What is the most common aluminium extrusion?
• Does aluminium extrusion rust?
• What causes aluminium to turn black?
• Does aluminium extrusion bend?
• Why choose a full service extrusion manufacturer?

What is aluminium extrusion?

Aluminium extrusions are a type of engineered material, manufactured from solid feedstocks of billet aluminium. The term ‘extrusion’ is used to cover everything from hollow tubing and channels, to semi hollow box sections, solid rods, and angled profiles, and is derived from the forming process of the same name.

Aluminium extrusions are characterised by their linear, uniform shape following the extrusion process. They are available in solid, semi-hollow, and hollow profile forms, and can be purchased and custom-manufactured to a range of shapes, including: square, round, T-profile, U-profile, Z-profile, I-beam, drawn/seamless tubes, slotted channels, extruded angles, and more.

Standard profiles are manufactured to a range of sizes and can be ordered and cut to length to suit your project requirements. We can manufacture custom extrusions to your exact specifications; to learn more about our extrusion manufacturing expertise and offering, contact our experts for more information and to request a free, no obligation quote.

Why are aluminium extrusions used?

Aluminium extrusions and extruded profiles are used frequently due to the versatility that aluminium alloys offer. While physical properties vary between alloys, aluminium extrusions offer numerous benefits for manufacturing and product design, including:

• Design flexibility: Unlike traditional metalworking methods, extrusion processes allow for aluminium to be shaped into customised profiles with built-in channels and slots, in a single manufacturing process. This can significantly reduce the volume of secondary processing required, improving efficiency and reducing total costs of production. Designers and manufacturers can therefore leverage the simplicity of extrusion processes to their advantage, implementing complex extruded components into designs without cost or production restrictions.
• Scalability: Whether standard extruded profiles or custom extrusions are required, once a die has been created, aluminium extrusions can be produced in volume with high-precision and consistency, and unmatched scales of economy.
• Strength & Lightweight Properties: Aluminium extrusions leverage the durable and high strength properties of aluminium while being significantly lighter than steel and other material counterparts. This means extruded aluminium profiles can support high loads while keeping weight to a minimum, reducing necessary feedstocks to create a cost-effective, lightweight material.
• Corrosion Resistance & Durability: Aluminium is naturally resistant to corrosion and rust, forming a surface barrier of aluminium oxide that protects against structural wear. As a result, aluminium extrusions are ideal for outdoor applications or uses where components are exposed to prolonged moisture and chemical exposure.
• Suitability for secondary processing & finishing: From CNC bending/forming, welding, and mitring, to CNC milling, drilling, powder coating and painting, aluminium extrusions can be processed through a wide range of secondary engineering methods.

We supply businesses with standard and custom aluminium extrusions manufactured in house up to 10m in length, providing a complete range of extrusion engineering services, including: product design, stock holding and supply, cut to length, mitring, welding, CNC milling, CNC drilling, profile bending/forming, vibro deburring, powder coating and painting, laser etching, sub-assembly, and distribution.We specialise in high-volume, time sensitive and repeat orders for aluminium extrusions and engineered aluminium extrusion components. Contact us today for more information and enquiries.

How are aluminium extrusions made?

Guide to the aluminium extrusion manufacturing process:

1. Designing the Die

Dies are fundamental to the manufacturing process of extruded components. Whether a simple tube, I-beam or complex extrusion is required, the extrusion process begins by selecting or designing the die for the feedstock to be forced through. Dies for aluminium extrusions mirror the cross section of the final product, meaning any channels or openings are formed by using either a solid, semi-hollow, or hollow die to required shape.

2. Heating the Aluminium

To begin the forming process, the aluminium billet/feedstock must be heated to a high temperature (typically up to 496°C) to make them malleable enough for extrusion. Crucially the temperature is above the crystallisation point for the aluminium alloy chosen to ensure that the feedstock does not harden during the extrusion process to ensure ease of manufacturing.

3. Extruding the Aluminium & cooling

The heated aluminium is forced through the die using a ram, forming the aluminium to the required shape. Once the extrusion has exited the die, it begins to cool for further engineering processes to occur once hardened.

What are the limitations with aluminium extrusion?

While incredibly versatile, aluminium extrusions do have some limitations:

• Size Restrictions: The size of the extruder and die can limit available profile dimensions. At Edmo, we have the capabilities to manufacture standard and custom aluminium extrusions up to 10m length.
• Initial Costs: Custom dies can prove costly for initial investment. At Edmo, we have extensive experience in providing high-volume, cost-effective aluminium extrusion services without compromise to quality, serving leading businesses across the world.

What products are made from aluminium extrusion?

Aluminium extrusions are used in an extensive range of industries, to manufacture high-quality, durable products found throughout the world. At Edmo, we support businesses in a wide range of sectors with aluminium extrusion manufacturing and engineering services, supporting in the manufacture of:

• Construction: Window frames, architectural trims, structural framing and stair rails
• Transportation: Lightweight components for automotive and aerospace industries.
• Consumer Goods: Furniture, lighting fixtures, and appliances.
• Electronics: Heat sinks and enclosures.
• Accessibility Aids: Stair lifts, grab rails, bath rails, stair rails.
• Street lighting & signage: Traffic light poles, street signage poles and street light poles.

Regardless of your project or manufacturing needs, if you require high-quality, cost-effective aluminium extrusions and manufacturing services – we have you covered. Experts in high volume aluminium extrusion services, contact us today to discuss your service requirements.

What types of aluminium extrusion can be made?

Whether you require standard profile extrusions or a custom designed option, there are countless types of aluminium extrusion available to suit your project. The type of extrusion manufactured depends on the shape of the die used. At Edmo, we have a wide range of standard dies for conventional extrusion profiles including round, square and I-beam extrusions, and the capability to manufacture custom dies for bespoke extrusion manufacturing.

The most common types/categories of extrusions:

• Angled extrusions: Angled extrusions are common in construction, machinery, and other industrial settings and are often used for structural and framing applications. The exact angle and profile manufactured can be tailored to your requirements, with 90°/’L’ shaped extrusions commonly requested.
• Channels: Channels are frequently used for framing, structural applications, and creating slots for fastening or assembly. They are common in construction, shelving, and support structures. Profiles such as U-shaped or C-shaped are widely used, though the exact channel profile can be tailored to suit your design requirements with the use of custom extrusion dies.
• Tubing/pipes: Aluminium tubes and pipes are commonly sourced and requested, and can be manufactured to a range of diameters and thicknesses. At Edmo, our cut to length services are frequently used to cut round aluminium tubing/extrusions to specific lengths. Aluminium tubing is used throughout plumbing, aerospace, automotive, and mechanical systems.
• Structural aluminium: Structural aluminium extrusions are typically heavy-duty extrusions designed for load-bearing applications. They include beams, columns, and other components used in buildings (such as balconies) and public infrastructure including bridges. At Edmo, we manufacture high-quality extrusions for structural projects and applications.
• Extruded beams: Extruded beams can be manufactured and sourced in solid, hollow, or semi-hollow forms, with I-beam, H-beam, T-beam, and C-beam frequently requested. At Edmo, we hold stocks of standard dies for extruded beam manufacturing, and can manufacture bespoke extruded beams with our custom die manufacturing facilities.

Require standard or custom extrusions?Speak to our experts to discuss your high volume extrusion manufacturing requirements.

Does aluminium extrusion rust?

As an engineered material of aluminium, aluminium extrusions share the same anti-rusting properties. In other words, aluminium extrusions do not rust or corrode. Aluminium is naturally resistant to corrosion, forming a layer of aluminium oxide on its surface when exposed to the atmosphere.

What causes aluminium to turn black?

When exposed to atmospheric conditions, aluminium oxidises, forming a layer of aluminium oxide on the surface of the metal. The surface of aluminium can range in shade, from dull grey to silver when oxidised, with this effect caused by light scattering on the surface of the metal.

Aluminium can turn black in extreme heat conditions, forming a thicker, darker oxide layer that sometimes appears black. This can also occur from exposure to sulfur compounds, pollution, or industrial environments, that can result in aluminium sulfides or hydroxides forming instead of an aluminium oxide layer.

The appearance of aluminium extrusions can be tailored through the use of surface treatment techniques such as anodising, electrochemical blackening, powder coating, and painting. At Edmo, we offer comprehensive powder coating and painting services to provide complete protection and colour choice for your components.

Alongside standard black, white and grey shades, we offer a complete range of powder coating colours including reds, blues, greens, and yellow for a cost effective, sustainable solution for component finishing.

Does aluminium extrusion bend?

Aluminium extrusions can bend. Whether this is desired or not must be determined in your product design phase. At Edmo, we hold the capabilities to bend and form aluminium extrusions to your design requirements. If extrusions are not designed to bend, the dimensions and design of your extrusion may be factored in before the forming process to provide enhanced integrity to support your final products functionality.

Why choose a full service extrusion manufacturer?

Sourcing aluminium extrusions is typically not your end goal. For brands and manufacturers, further engineering processes such as milling, fabrication, finishing and assembly are required to create products to their end form.

By working with a full service extrusion manufacturer, you can significantly reduce your lead times and total manufacturing costs, reducing the volume of infrastructure and equipment investments. By working closely with a single supplier, you can remove unnecessary hassle in supplier chains to streamline your supply and production processes.

At Edmo, we provide full service solutions for aluminium extrusion manufacturing. We specialise in supplying high-quality, high-volume extrusion services for leading brands across the world. We pride ourselves on delivering tailored solutions to fit your service requirements, ensuring fast, consistent and precision manufacturing services that are cost effective.