Custom Aluminum Extrusion Profiles

Profall is an Italian Company specialized in the production and supply of standard and custom aluminum extrusion profiles. We employ different aluminum alloys to extrude high quality profiles for any specific need, even with high technical content. We ship worldwide.

Profall follows the Italian tradition of aluminum extrusion to produce high quality profiles, even with thin and thinnest size that is difficult to find from the average extrusion supplier. Our technical staff is available to embrace the customer’s requirements and design the perfect, custom aluminum extrusion profile.

Aluminium alloys for custom extrusions

At Profall, our custom aluminum extrusion profiles are manufactured using soft alloys from the 1000, 3000, and 6000 series, carefully selected to deliver the right balance of conductivity, strength, and corrosion resistance for each application. By choosing the most suitable alloy, we guarantee the performance and durability of every bespoke aluminium extrusion we produce.

1000 series alloys (1050, 1070)

With a purity rating above 99.5%, these alloys stand out for their excellent electrical and thermal conductivity and outstanding corrosion resistance. Their superior workability makes them ideal for custom aluminium profiles in the electrical and electromechanical industries, as well as chemical and food sectors.

3000 series alloys (3003, 3103, 3004)

Manganese-based alloys with very high corrosion resistance, often used in automotive applications and heat exchangers thanks to their brazing capability. They are the right choice for custom extruded aluminum profiles that require durability and structural reliability in demanding environments.

6000 series alloys (6060, 6063, 6005)

Containing magnesium and silicon, these alloys are highly versatile and widely used in the extrusion industry. They ensure excellent weldability, good mechanical strength, and a fine surface finish, making them the perfect material for custom aluminum extrusion profiles in architecture, transportation, lighting, and industrial design.

Get your free PDF catalog containing the physical and mechanical properties of all aluminum alloys we use.

Machining and finishing options

At Profall, extrusion is just the beginning. To provide fully finished bespoke aluminium extrusion solutions, we integrate a wide range of machining and surface treatments that make our custom aluminum extrusion profiles ready for immediate use in your production lines.

Cutting, drilling, and punching

Our profiles can be cut to size, drilled, or punched with the required patterns and dimensions. This ensures that every custom aluminium profile is delivered ready for assembly, reducing on-site processing and saving time and cost for our clients.

Bending and curving

Thanks to our expertise in thin-walled extrusions, we can perform bending and curving operations on even the most delicate geometries. This capability is particularly valuable in the furniture, lighting, and architectural sectors, where complex shapes are often required.

Anodizing

Anodizing is one of the most requested treatments for our custom extruded aluminum profiles. It improves surface hardness, enhances corrosion resistance, and provides an aesthetic finish. Different colors and thicknesses are available, making it an ideal solution for both technical and decorative applications.

Painting and powder coating

Painting and powder coating give the profile a uniform, durable, and customizable surface. These treatments not only improve corrosion resistance but also allow clients to choose specific colors to match their brand or project requirements.

Polishing and special finishes

For architectural and design purposes, we provide mechanical polishing and brushing, delivering profiles with a refined look. Special finishes can also be applied to meet unique aesthetic or functional demands.

By combining extrusion with these advanced treatments, Profall delivers custom aluminum extrusion profiles that integrate seamlessly into multiple industrial sectors — from automotive to electronics, furniture, lighting, and marine applications.

Why choose Profall for custom aluminum extrusions?

Choosing Profall means relying on a trusted partner capable of producing custom aluminum extrusion profiles with a level of precision and complexity that many suppliers cannot match. We are specialists in thin-walled and technically demanding profiles, offering solutions that combine innovation, quality, and flexibility.

Our main competitive advantages include:

• Complex and thin-walled profiles: we manufacture custom extruded aluminum profiles with extremely reduced thicknesses, ideal for advanced applications where weight and space constraints are critical.

• End-to-end customization: from feasibility studies and collaborative design to prototyping and full-scale production, we deliver truly bespoke aluminium extrusion solutions.

• Flexible production volumes: whether you need a single prototype or a large-scale series, our processes adapt to your requirements.

• Continuous technical support: our engineering team works closely with customers throughout the project lifecycle, ensuring performance and cost optimization.

• Made in Italy quality: a unique combination of Italian tradition in extrusion and continuous technological innovation.

Industries we serve

Thanks to their versatility and performance, our custom aluminum extrusion solutions are integrated into multiple industries worldwide:

Automotive

Lightweight and durable profiles designed to reduce vehicle weight, improve efficiency, and contribute to sustainability goals. From structural components to decorative trims, Profall develops tailor-made custom aluminium profiles for the mobility sector.

Electronics

Alloys with high thermal and electrical conductivity are used for heat sinks, connectors, and housings. Thin and precise custom aluminum extrusion profiles ensure optimal heat dissipation and reliable performance in demanding electronic applications.

Furniture & Interior Design

Refined, aesthetic, and functional profiles, often enhanced with anodized or polished finishes. PROFALL supplies custom extruded aluminum profiles that combine strength, design, and versatility for architectural and furnishing projects.

Lighting

Thin-walled and complex extrusions specifically engineered for LED systems, spotlights, and architectural lighting. Our bespoke aluminium extrusion solutions provide optimal housing for light sources while ensuring excellent thermal management.

Marine Applications

We supply marine aluminium alloys with exceptional corrosion resistance, making them the perfect choice for shipbuilding, offshore structures, and components exposed to saltwater environments. These alloys guarantee long-lasting durability without compromising lightness.