Low Volume Aluminum Extrusion Services

Combine with CNC and Other Methods Global Delivery in 2-3 Weeks

Low Volume Aluminum Extrusion Services

Combine with CNC and Other Methods

Global Delivery in 2-3 Weeks

Aluminum extrusion is a highly effective process used to create aluminum objects with specific cross-sectional profiles.

The process begins with heating a solid cylindrical block of aluminum, known as a billet, to a moldable state without melting it. The heated billet is then forced through a die using a powerful ram, resulting in the desired shape being produced on the other end.

Aluminum extrusion allows product designers to capitalize on the unique properties of aluminum, such as its lightweight nature, exceptional strength, corrosion resistance, and compatibility with various surface finishes.

Extruded aluminum finds extensive applications in industries such as architecture, automotive, aerospace, transportation, medical devices, and many more.

One of the notable advantages of aluminum extrusion is the relatively lower cost of new die and tooling compared to similar processes. Moreover, it is an ideal choice for medium to high volume production. Rely on our professional expertise in aluminum extrusion for your manufacturing needs.

Customization

We offer custom aluminum extrusion profiles combined with CNC milling, turning, and bending for end-to-end part manufacturing.

Low Volume

No high MOQs here. OYA is the top choice for lower volume extrusions. Need a one-off prototype or just a few hundred units? We've got you covered.

Fast Delivery

Avoid the lengthy wait of 30+ days for extrusion mold and profile manufacturing. At OYA, we deliver results in half the industry-standard time, or even quicker.

About Our Aluminum Extrusion Capabilities

Gensun specializes in extruding a wide range of standard and custom profiles. Our capabilities include:

Utilizing alloys like 6061, 6063, and other 6xxx series alloys
Solid profiles crafted from 2xxx and 7xxx alloys
CNC machining services for precise finishing of extruded profiles
Secondary operations such as cutting, drilling, and more
Comprehensive finishing services including anodizing, painting, powder coating, and beyond

To inquire about our services, discuss the manufacturability of your design, or request a quote, please contact us. We are eager to assist you.

What is Aluminum Extrusion ?

Aluminum extrusion is a process that shapes aluminum material by forcing it through a shaped opening in a die. The result is an elongated piece with a continuous cross-sectional profile, which can be intricate and complex. To simplify the concept, imagine how pasta shapes or Play-Doh are made. Dough is fed into a chamber, pressure is applied, and strands are squeezed out of a small hole, with the attachment determining the cross-section of the strands, such as tagliatelle or penne.

However, aluminum billets are not as malleable as pasta dough, so the extrusion process requires significant force, often through hydraulic pressure, and sometimes involves the application of heat.

How Does Aluminum Extrusion Work?

Aluminum extrusion can be performed through two methods: hot extrusion and cold extrusion. Each method offers unique advantages. Hot extrusion allows for high volumes of aluminum to be quickly fed into the die at lower pressure. In contrast, cold extrusion produces mechanically robust parts with excellent surface finish and oxidation resistance.

For hot extrusion, aluminum billets are first cut to size and then heated to a temperature of 300 °C to 600 °C. This temperature renders the metal malleable without melting it. The heated billets are then forced into the die by a hydraulic ram, applying immense pressure of around 10,000,000 pounds. The extrusions are subsequently cooled on a cooling table and cut into desired lengths as per customer specifications. Heat treatment can also be employed to enhance the aluminum's hardness.

Common Extrusion Applications

Aerospace
Automotive
Trains
Ships

Construction Industry
Medical Devices
Display Industry

Heatsink
Electronics
Automation

Standard Aluminum Extrusion Profiles

Custom aluminum extrusion profiles can be tailored to any desired 2D cross-sectional shape. However, there are also standard aluminum extrusion profiles that are widely used and suitable for a variety of projects. These include extruded aluminum bars and extruded aluminum channels, which come in various forms and sizes.

Standard profiles include:

Circular bar

Square bar

Circular tube

Square tube

L-shape

U-shape

T-shape

C-shape

J-shape

F-shape

Profiles also come in standard sizes and series. These include:

2020 aluminum extrusion (20 mm x 20 mm)

80/20 aluminum extrusion (T-slot aluminum extrusion)

2040 aluminum extrusion (20 mm x 40 mm)

3030 aluminum extrusion (30 mm x 30 mm)

Finishing Options for Aluminum Extrusions

Basic mechanical finishing: Treatments like buffing, bead blasting, and grinding can be carried out to adjust the surface quality of aluminum extrusions, sometimes in preparation for other surface finishes.
Anodization: Aluminum extrusions can be anodized to give them a scratch-resistant and oxidization-resistant coating with an excellent cosmetic appearance.
Painting: Whether the part needs a matte, gloss, or textured finish, painting is an effective way to alter the color and surface appearance of an aluminum extrusion.
Powder coating: Powder coating is a suitable alternative to anodizing, giving excellent chemical resistance and consistency of tone.
Silk-screen printing: One of the simplest ways to add text and logos to aluminum extrusions, silk-screen printing is cheaper than machine-based finishing procedures.
Laser engraving: Laser engraving can be used to add detail, including text, to an extrusion, and it will not rub off over time. It is therefore useful for essential features like part serial numbers.

Fast and High Quality

Applications of Aluminum Extrusion

Industrial: Extruded aluminum can be used to make industrial equipment like workbenches and carts, as well as extruded aluminum frames / extruded aluminum framing. Standard framing systems include extruded aluminum T-slot structural framing (80/20 extruded aluminum framing).
Construction: Architecture and construction provide several uses for aluminum extrusion such as extruded aluminum rails, balustrades, and ladders.
Electrical: Aluminum is electrically conductive and is therefore useful in its extruded form for lighting components such as LED aluminum extrusions, solar panel support structures, and more.
Transport: Extruded aluminum is good for fabricating items like automotive, horse, and boat trailers.

Aluminum & Plastic Extrusion FAQ

Why should I use OYA over a dedicated extrusion company?

We specialize in low-volume manufacturing. If you require a small to medium-size order, other companies may not accommodate your needs.

Can I specify an aluminum alloy?

Our most commonly used alloys are 6061 and 6063, which contain high levels of magnesium and silicone. Both are highly corrosion resistant.

You may specify a different aluminum alloy, and we will review the feasibility when providing you with a quotation.

Who manufactures the extrusions?

We have a selection of trusted extrusion partners who fulfill our orders, but OYA will do post-machining and check the parts before shipment.

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