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:
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:
To get a better idea on what you can obtain from aluminum extrusion, take a look at our Aluminum Extrusion Catalog.
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.
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.
A solid aluminum alloy billet is cut and heated to 400–500°C, becoming malleable but not molten.
Lubricants are applied to prevent sticking during extrusion. The billet is then loaded into the press.
The hydraulic ram applies up to 15,000 tons of pressure to force the billet into the container.
The softened billet is pushed through the die, emerging in the final profile shape. Nitrogen gas may be used to create an inert atmosphere.
The extruded aluminum profile is cooled with air or water on a run-out table.
A hot saw cuts the profile to manageable table lengths while still hot.
The profile is further cooled using fans until it reaches ambient temperature.
Minor twisting is corrected through stretching, which also enhances material strength.
Profiles are cut to exact customer specifications.
Heat-treated in an oven to achieve T5 or T6 temper — improving mechanical performance.
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 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.
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.
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:
Customization is really Profall flagship. Getting a bit into details, it means that:
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.
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:
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:
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 |
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.
