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What is extruded aluminum?

how does aluminum extrusion work

From window frames and drawer handles to structural supports and LED housings, aluminum extrusions are everywhere. Their popularity continues to grow across industries due to their light weight, corrosion resistance, and design flexibility.

But where do aluminum extrusions come from? And how does aluminum extrusion work in detail?

 Explore this page to learn:

 

What is aluminum extrusion?

Aluminum extrusion is a process used to transform aluminum alloy into objects by forcing the material through a die under high pressure with a specific cross-sectional profile, to create complex shapes. The process involves heating a cylindrical billet of aluminum to a temperature where it becomes malleable, and then pushing it through a die to produce the desired shape.

Aluminum’s malleability allows it to be easily machined and cast; at the same time, being one-third the density of steel, the resulting objects are characterized by remarkable strength and stability.

During the extrusion process, a ram pushes the aluminum through the die and it emerges from the die opening in the same shape as the die. It is then pulled out along a runout table.

The resulting shapes can be either simple or complex depending on the die shape, and can also have very tiny dimensional tolerances, like those Profall is able to achieve. In fact, a variety of aluminum profiles and objects can come out of the extrusion process. We can divide them into three main categories:

  • Solid, with no enclosed voids or openings like round tubes, beams, and angles
  • Hollow, with one or more voids such as square or rectangular tubes
  • Semi-hollow, with a partially enclosed void like C-channels

To get a better idea on what you can obtain from aluminum extrusion, take a look at our Aluminum Extrusion Catalog.

 

Whichever extruded profile you need, choose Profall: we ship worldwide!

How does aluminum extrusion work?

If you're wondering how does aluminum extrusion work, here’s a clear and concise explanation. The aluminum extrusion process transforms a cylindrical billet into a defined profile using pressure, heat, and precision engineering. The result is what we call extruded aluminum — lightweight, strong, corrosion-resistant, and fully customizable for a wide range of applications.

The following 11 steps briefly explain how is extruded aluminum made.

1. Die Design and Preheating

Every extrusion begins with a custom-designed die, typically made of H13 steel. The die is preheated to 450–500°C to ensure consistent metal flow and durability.

2. Billet Preheating

A solid aluminum alloy billet is cut and heated to 400–500°C, becoming malleable but not molten.

3. Lubrication and Transfer

Lubricants are applied to prevent sticking during extrusion. The billet is then loaded into the press.

4. Applying Pressure

The hydraulic ram applies up to 15,000 tons of pressure to force the billet into the container.

5. Extrusion Through the Die

The softened billet is pushed through the die, emerging in the final profile shape. Nitrogen gas may be used to create an inert atmosphere.

6. Initial Cooling

The extruded aluminum profile is cooled with air or water on a run-out table.

7. Shearing to Length

A hot saw cuts the profile to manageable table lengths while still hot.

8. Cooling to Room Temperature

The profile is further cooled using fans until it reaches ambient temperature.

9. Stretching and Alignment

Minor twisting is corrected through stretching, which also enhances material strength.

10. Final Cutting

Profiles are cut to exact customer specifications.

11. Aging Treatment

Heat-treated in an oven to achieve T5 or T6 temper — improving mechanical performance.

 

what are aluminum extrusions used for

 

 

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What are aluminum extrusions used for?

Now that you clearly understand what is extruded aluminum, it's time to discover its wide range of applications across various sectors. The versatility of aluminum alloy extrusion lies in its ability to produce lightweight yet high-strength components with tight tolerances and customized profiles.

Here are the key sectors where extruded aluminum makes a difference:

Construction and architecture

  • Window and door frames

  • Curtain walls and façades

  • Handrails, balustrades, and staircases

  • Structural reinforcements in modular buildings

Thanks to its corrosion resistance and ease of assembly, extruded aluminum is a top choice in modern and sustainable architecture.

Automotive and transportation

  • Lightweight chassis and body components

  • Bumpers, crumple zones, and side-impact bars

  • Radiator enclosures and roof rails

  • EV battery enclosures and structural supports

Aluminum alloy extrusion supports automotive design goals like weight reduction, fuel efficiency, and crash safety.

Electronics and electrical engineering

  • Heat sinks for power electronics

  • LED lighting housings and totems

  • Cable management systems

  • Server racks and electronic enclosures

Its thermal conductivity and non-magnetic properties make extruded aluminum ideal for electronics and electrical systems.

Renewable energy and infrastructure

  • Solar panel frames and mounting systems

  • Wind turbine components

  • High-voltage transmission structures

  • Battery casing and cooling systems

Aluminum's high strength-to-weight ratio and resistance to outdoor conditions are essential in energy infrastructure.

Industrial machinery and automation

  • Modular framing systems

  • Conveyor guides and support rails

  • Machine guards and safety enclosures

  • Pneumatic and hydraulic housings

Custom aluminum extrusions simplify assembly, reduce machining, and offer long-term reliability under mechanical stress.

Whichever extruded profile you need, choose Profall: we ship worldwide!

How we make custom aluminum extrusions

Additional complexities may be applied during the extrusion process to customize the extruded parts. For example, pins or piercing mandrels are placed inside the die to create hollow sections.

Depending on the final use of the extrusion you require, you may also need some surface finishing to adjust the color, texture and brightness of the aluminum’s finish or to make it resistant to rust and corrosion.

We can divide surface finishing treatments into three main categories:

  • Anodization
  • Coating
  • Punching, drilling, cutting, etc.

 

aluminum alloy extrusion

 

Anodized aluminum

Anodization is a galvanic, or electrochemical, process that aims to create a layer of oxide on the surface of the extrusion. The final purpose is to improve aluminum’s resistance to corrosion caused by atmospheric agents or rust by improving surface emissivity. In addition, the layer of oxide makes the surface porous so that it can accept various colored dyes - from neutral tones to bronze shades ranging from light champagne to dark.

Powder coating

If you have specific aesthetic requirements, powder coating is the solution as it applies a layer of colored material upon the extrusion surface. It is commonly an epoxy or electrostatic polyester powder coating that adheres to the surface, which needs to undergo a secondary treatment to render the coating layer uniform.

Profall makes coated extrusions in all the RAL colors - including special aesthetic effects such as wood-like textures.

what is extruded aluminum

Punching, drilling, cutting aluminum

These are just three of the many available options that allow us to create a piece of extruded aluminum with the exact dimensions and specifications you need.

For instance, we can drill screw holes into a structural piece or cross machine fins to obtain a specific pin design.

Other mechanical and finishing processes include:

  • Shearing through a state-of-the-art software to transform the various profiles and match your needs
  • Aluminum packaging, with the chance of applying logos, bar codes and specific IDs

 

The tiniest dimensions on the aluminum market

Customization is really Profall flagship. Getting a bit into details, it means that:

  • You can choose among standard or special profiles in our catalog, and ask for customization
  • You can contact us to make fully tailor-made aluminum extrusions

Most part of the requests we receive is focused on the production of extruded aluminum pieces with extremely tiny dimensional tolerances, which are quite hard to find on the common aluminum market. For instance, tubes have standard dimensional tolerances of +/- 0.15 mm per side, but we can produce them also with smaller dimensions and all the mechanical characteristics and complexities you need.

 

Aluminum alloys

The choice of which alloy to use is directly depending on the final use of the extruded profiles and their mechanical features. At Profall we basically extrude aluminum from three different alloys:

  • 1000 series (1050 – 1070) with a minimum purity rating of 99.5% - these alloys have high electrical and thermal conductivity properties, and are extremely resistant to corrosion
  • 3000 series alloys (3003 – 3103 – 3004) are mainly made of Manganese - extremely resistant to corrosion, this series of alloys is mainly used in automotive applications and for braze welding purposes
  • 6000 series (6060 – 6063 – 6005), which contains Silicium and Magnesium, is easily processed and welded - one of the most used alloy is the 6063 aluminum, employed to manufacture square, rectangular and round bars and tubes.

 

You can learn more about this topic here: Aluminum Alloy Extrusion: How to Choose the Right Alloy for Your Product

 

The most common alloys requested by our clients are 1050, 1070, 3103 and 6060, with which we manufacture:

 

extruded aluminum

 

Advantages and disadvantages of extruded aluminum

As told above, extruded aluminum is widely recognized for its versatility and performance across multiple industries — from construction and transportation to electronics and energy. However, like any manufacturing solution, it comes with both strengths and limitations. Understanding these will help engineers and designers make more informed material choices for their specific applications.

The table below outlines the main advantages and disadvantages of aluminum alloy extrusion:

Aspect Advantages Disadvantages
Weight Extremely lightweight (~2.7 g/cm³), ideal for weight-sensitive designs Less suitable for applications requiring heavy mass or impact inertia
Corrosion Resistance Excellent, especially when anodized or coated May need additional protection in highly aggressive environments
Workability Easy to cut, drill, machine, and assemble Improper handling may cause deformation during extrusion
Thermal Conductivity Very good for heat dissipation in electronics and lighting Lower than copper for critical heat-transfer systems
Custom Design Capability Allows complex shapes, thin walls, and tight tolerances Higher upfront costs due to die design and tooling
Sustainability 100% recyclable with no loss of mechanical properties Recycling still requires energy, though significantly less than primary production
High-Volume Production Excellent dimensional consistency in mass production Less economical for small runs without amortizing tooling costs
Finish Compatibility Highly adaptable: anodizing, powder coating, decorative effects Some finishes require specific surface preparation or pre-treatment

 

Profall's excellence in extruded aluminum services

At Profall, we specialize in providing top-tier extruded aluminum services, tailored to meet the diverse needs of our clients. Our expertise in extrusion technology allows us to produce aluminum profiles with exceptional precision and quality, even with the most challenging shapes and sizes. 

Whether it's for construction, automotive, electronics, or any other industry requiring the strength, lightness, and corrosion resistance of aluminum, Profall stands out as your go-to partner. We offer a wide range of customizable solutions, from standard shapes to complex custom designs, ensuring that each product not only meets but exceeds our clients' expectations. 

With a commitment to innovation and customer satisfaction, Profall's extruded aluminum services are designed to deliver efficiency, durability, and aesthetic appeal. Choose Profall for all your extruded aluminum needs and experience a partnership that drives your projects to success.

 

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