Aluminum extrusions are highly versatile and offer numerous advantages over traditional metalworking techniques. They involve pushing or pulling an aluminum billet or log through a die to create a specific shape or profile. The extruded aluminum can then be cut to any desired length and processed through various finishing options.

Custom aluminum extrusions allow manufacturers to create unique and complex shapes and profiles that meet their needs. As a result, they are used in a wide range of industries, including construction, automotive, aerospace, and electronics.

This article will provide a step-by-step guide on how to get your custom aluminum extrusions right.

Step 1: Identify Your Design Requirements

Before you start the process, you need to identify the design requirements for your custom aluminum extrusions. This includes the dimensions, shapes, and any special features required for your project. During this phase, it’s important to work closely with your engineering team to ensure that your design meets the specific requirements of your application.

Step 2: Choose the Right Aluminum Alloy

Different alloys have different properties, such as strength, corrosion resistance, and thermal conductivity. Choose an alloy that meets your project’s demands, and consider factors such as the intended application, expected loads, and desired lifespan.

Step 3: Select the Right Extrusion Manufacturer

Look for a manufacturer with a proven track record of delivering high-quality custom extrusions. You may survey the company expertise, production capabilities, and quality control processes.

Step 4: Work With the Manufacturer on Tooling Design

A well-designed tooling can help reduce lead times, minimize waste, and improve the overall quality of the extruded profiles. Thus, make sure to work closely with the manufacturer on the tooling design. Consider also the complexity of the profile and the desired production volume.

Step 5: Understand the Extrusion Process

Familiarizing yourself with the extrusion process helps you understand the critical variables that can affect the quality of your components. Here are the key steps in the process:

Billet Heating

The heating process makes the aluminum more malleable, allowing it to be extruded without cracking or breaking. The exact temperature for heating the billet depends on the specific alloy used and the die’s shape.

Die Preparation

A die is a specially designed metal tool that determines the shape and size of the extruded aluminum. Therefore, it must be carefully designed to ensure that the aluminum flows evenly and that the final extrusion meets the required tolerances.


The hydraulic press applies pressure to the billet, forcing it through the die and creating the desired shape. Finally, the extruded aluminum emerges from the other side of the die and is cut to the desired length.


Cooling is essential to ensure that the aluminum retains its shape and strength. Depending on the specific alloy and the complexity of the extrusion, the cooling process can take anywhere from a few minutes to several hours.

Step 6: Finish Your Custom Aluminum Extrusions

Some common finishing options include anodizing, painting, powder coating, and others. Collaborate closely with your manufacturer to select the right finishing option based on your aesthetic and durability requirements.

Step 7: Implement Quality Control Processes

Quality control processes include testing and inspection and quality assurance initiatives. These can help identify and address defects or inconsistencies in the extruded profiles.

Choose Richardson Metals for Reliable Custom Aluminum Extrusions

Ready to get started on your custom aluminum extrusion project? Richardson Metals is the best choice! With our decades of experience and state-of-the-art facility, we can provide high-quality extrusions and processing services to meet your needs.

Contact us today to learn more about our capabilities and discuss your project requirements. You can also request a quote to get started on partnering with us.

Leave a Reply

Your email address will not be published. Required fields are marked *