Design Considerations for Custom Aluminium Extrusion Sections

  • By:Naview
  • Date:2024-04-30

Custom aluminium extrusion sections offer a wide range of benefits for various applications. They provide a combination of strength, durability, and versatility, making them suitable for industries ranging from automotive to construction. However, designing custom aluminium extrusions requires careful consideration of several key factors to ensure optimal performance and functionality.

Tolerances and Precision

Tolerances refer to the allowable variation in the dimensions of the extruded section. Precision extrusions demand tighter tolerances, reducing gaps and ensuring a perfect fit with other components. Factors such as die design, extrusion speed, and temperature control influence tolerance levels. Tighter tolerances lead to higher precision but may increase production costs.

Wall Thickness and Strength

Wall thickness significantly affects the strength and rigidity of the extrusion. Thicker walls provide greater structural integrity but require more material and can be more expensive to produce. Thinner walls offer weight reduction and increased efficiency but may compromise strength. The ideal wall thickness depends on the application and required load-bearing capacity.

Shape and Complexity

Extrusions come in a vast array of shapes, ranging from simple channels to intricate profiles. Complex shapes require more sophisticated dies and may involve additional production steps. The shape of the extrusion should be carefully designed to optimize functionality and minimize production costs. Sharp corners and abrupt transitions can create stress points and weaken the extrusion.

Surface Finish

The surface finish of the extrusion can impact both aesthetics and performance. Various finishes are available, including clear anodizing, powder coating, and painting. An anodized finish provides corrosion resistance and enhanced durability, while powder coating or painting offers a wide range of color options and can improve abrasion resistance.

Material Properties

Aluminium alloys used for extrusion vary in their mechanical properties and chemical composition. The choice of alloy depends on the specific requirements of the application. Some alloys offer high strength, while others provide corrosion resistance or a particular surface finish. It is essential to select the appropriate alloy to ensure the desired performance and longevity of the extrusion.

Die Design

The die is a critical component in the extrusion process, determining the final shape of the section. Careful design of the die is crucial to achieve dimensional accuracy, consistency, and the desired material flow characteristics. The shape of the die orifices, the land length, and the radii all influence the properties of the extruded section.

Production Considerations

In addition to design factors, production considerations also play a role in the design of custom aluminium extrusions. The extrusion press capacity, available tooling, and production efficiency must be taken into account. Extrusion speed and temperature control influence the quality and properties of the extrudate. Optimization of these parameters ensures efficient production and minimizes production defects.


Designing custom aluminium extrusion sections requires a comprehensive understanding of the material properties, production capabilities, and the specific requirements of the application. By carefully considering the design factors discussed above, engineers and designers can create extrusions that meet their exact specifications and deliver optimal performance. Custom aluminium extrusions offer a versatile solution for a wide range of industries, providing a combination of strength, durability, and precision that makes them an ideal choice for complex and demanding applications.





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