Raw Materials · Aluminum Products

Customized Aluminum Extrusion Profile

A custom profile starts with a die, and the die starts with a drawing that respects how aluminum flows. Wall balance, corner radii and the circumscribed circle decide whether the section extrudes cleanly or warps through the whole run.

Die design reviewed before it is cut. We check wall balance, tongue ratios and the circumscribed circle against the press before the die is ordered, because a die that cannot fill is a die that has to be cut twice.
Alloys matched to the section. 6063 for thin, decorative sections, 6061 and 6082 where the profile is structural, machined, or anodized to a deep colour.
Fabrication in the same order. Cutting, drilling, tapping, bending and CNC finishing are quoted with the extrusion, so the parts arrive ready to assemble.
Finish after fabrication. Anodizing, powder coating or electrophoresis applied after machining, so the coating covers the finished part rather than being cut through.

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The Forms We Supply

Four routes cover most of what we quote. Each is a different mill or process route, so the size window and the lead time differ even where the grade looks similar.

Structural and hollow sections

Multi-void sections with balanced walls, designed so the die fills evenly and the profile stays straight through the run.

Frames, beams, battery housings

Heat sinks and finned profiles

Fins extruded as part of the section, with the fin spacing and root thickness set by the die rather than by a later machining step.

Electronics cooling, LED luminaires

Architectural and trim sections

Purpose-made mullions, trims and handrails that have to meet an existing building or product detail.

Facades, interiors, shopfitting

Machined and fabricated profiles

Extrusion plus CNC drilling, tapping, bending and anodizing, supplied as a finished part rather than a length of metal.

Automation parts, enclosures, transport

Size Range and Standard

Custom extrusion is quoted from the drawing plus the quantity. Tooling is a one-off cost, and the per-metre price falls as the run gets longer, so the two are always quoted together.

Swipe the table sideways for the notes →

Parameter	Range	What decides it
Profile weight	From roughly 0.2 kg/m upwards	Weight per metre drives the press size and the price per metre.
Circumscribed circle	Up to the press capacity, confirmed per section	A section that does not fit the container cannot be extruded at any price.
Alloys	6063, 6061, 6082, 6005, 7005	Strength, finish and weldability trade off against each other in the alloy choice.
Temper	T4, T5, T6	T6 for machined and loaded parts; T5 for architectural and frame sections.
Length	Cut to length from the extrusion run	Cutting after ageing avoids marking the finished surface.
Finishes	Anodized (clear or colour), powder coated, electrophoresis	Deep colour anodizing needs a tighter alloy and a better surface than clear.

Products' Properties and Advantages

What separates a good custom extrusion from a difficult one is decided on the drawing, before any aluminum is heated.

Wall balance, not just wall thickness

A section with one thick wall and one thin wall cools unevenly and twists. Balanced walls extrude straight and hold tolerance.

Radii and tongues

Sharp internal corners and long thin tongues wear the die and limit the run length. Rounded corners cost nothing and last.

Hollow sections need a porthole or bridge die

That changes tooling cost and the achievable wall. It is a design decision with a price attached, not a manufacturing detail.

The finish follows the alloy

Deep anodizing colours need a tighter chemistry and a better surface finish; specifying the colour after choosing the alloy can force a change.

How We Help Customers

Custom profiles are quoted from a drawing and a quantity. These are the four points we settle before the die is ordered.

Send the section drawing with the tolerances

Dimensions, wall, radii and the tolerance class. A DXF or a dimensioned PDF is enough to review.

Agree the alloy and temper

6063-T5 for architectural, 6061-T6 for structural or machined parts, 6082 where strength and anodizing quality both matter.

Confirm the die and the run length

Tooling is quoted once; the per-metre price depends on the total quantity, so the two are decided together.

Fix fabrication and finish before extrusion

Machining, bending and the finish are scheduled in that order, so nothing is cut or drilled after anodizing.

Real Applications

Custom extrusions turn up wherever a standard section is close but not right, and the difference is worth a die.

Heat sinks and battery housings

Finned and hollow sections where the geometry is the function and a standard profile cannot carry it.

Automotive and transport components

Structural sections in 6061 or 6082, extruded, machined and anodized as a finished part.

Architectural and interior systems

Purpose-made mullions, trims and handrails that have to meet an existing building detail.

Machine frames and automation

Frames with integrated cable channels, mounting faces and locating features that would otherwise need welding.