Tips for Cutting and Installing Curved Aluminum Extrusions

Aluminum extrusions offer a lightweight, durable, and versatile solution for various applications. However, cutting and installing curved aluminum extrusions can be a challenging task that requires specialized techniques and equipment. This article provides comprehensive tips to guide you through the process of cutting and installing curved aluminum extrusions effectively.

Measurement and Layout

Before cutting, it is crucial to take accurate measurements and mark the desired cut lines on the aluminum extrusion. Use a tape measure and a straightedge to ensure precision. For curved cuts, consider using a template or a flexible ruler to mark the curve accurately.

Cutting Techniques

There are several cutting methods suitable for curved aluminum extrusions.

Cold Sawing:

Cold sawing involves using a circular saw with a carbide-tipped blade. It is a relatively quick and efficient method, but it can generate heat and burrs.

Band Sawing:

Band sawing uses a continuous band saw blade to cut the extrusion. Band sawing offers more flexibility for cutting complex curves and can produce smoother cuts.

Waterjet Cutting:

Waterjet cutting utilizes a high-pressure water stream mixed with abrasive particles to cut the material. Waterjet cutting provides precise and burr-free cuts, but it can be more expensive.

Bending Techniques

After cutting, the aluminum extrusion may need to be bent to achieve the desired curved shape. Several bending techniques can be employed.

Press Brake Bending:

Press brake bending involves using a press brake machine to apply force and bend the extrusion along a specific angle.

Roll Bending:

Roll bending uses a series of rollers to gradually bend the extrusion into the required curvature.

Hand Bending:

For smaller curves, hand bending can be performed using a vice grip or a bending tool.

Installation Techniques

Proper installation ensures the structural integrity and performance of the curved aluminum extrusion.

Drilling:

Drilling pilot holes before installing the extrusion helps prevent cracking or deformation.

Assembly:

Curved aluminum extrusions can be assembled using various techniques, such as welding, riveting, or bolting.

Sealing:

Apply sealant around the edges of the installed extrusion to prevent water penetration and maintain durability.

Safety Precautions

When working with curved aluminum extrusions, safety precautions are essential.

Wear protective gear, including eye protection, gloves, and appropriate clothing.

Use sharp cutting tools and inspect them regularly to ensure proper cutting performance.

Securely hold the extrusion in place before cutting or bending to prevent accidents.

Conclusion

Cutting and installing curved aluminum extrusions require careful planning, specialized techniques, and safety precautions. By following the tips outlined in this article, you can ensure the successful execution of your project and achieve the desired results.