Shape the Future:
7TO ASTEPS
SUCCESSFUL
ALUMINUM
EXTRUSION
DESIGN
ProfilePrecisionExtrusions.com
TABLE OF CONTENTS
INTRODUCTION
Step 1: Fleshing out Your Idea 04
Step 2: Finding the Right Partner 08
Step 3: Final Design Quote 11
Step 4: Financial Considerations 14
Step 5: Framework of the Project 16
Step 6: Finalizing Your Creation 18
Step 7: Forging Ahead with Production 19
CONCLUSION
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INTRODUCTION
Profile Precision Extrusions (PPE) has been your partner in precision
aluminum extrusions since 1982. With over 5,000 successful
custom-extruded aluminum designs, we've been the go-to choice for
industry leaders like 3M Healthcare, Collins Aerospace, and Echo, Inc. But
we're not just about big corporations; we're equally committed to
empowering small businesses and entrepreneurs like you.
In this eBook, we distill over four decades of expertise into practical
insights, offering you a seamless path to turning your aluminum
extrusion ideas into reality. We review over 100 new designs every
month, learning and adapting to stay at the forefront of innovation.
Let's turn your ideas into reality, with precision and ease.
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STEP 1
Fleshing Out
Your Idea
A vast array of industries utilize aluminum
shapes and extruded aluminum tubing, and
your project might be a perfect candidate for
aluminum extrusion. Or, it might not. How do
you find out whether or not it’s a good fit?
Understanding some of the basics of the
process and conveying your requirements to
a potential partner is crucial. Here are some
tips to help you flesh out your idea and
determine its suitability for aluminum
extrusion manufacturing.
When we evaluate new designs, we look for:
Circle Size
The maximum size of parts an extrusion press can
manufacture, circle size describes the largest circle that
can be drawn around the extrusion design.
Uniform Wall Thickness
A design is much easier to produce if the wall
thicknesses are uniform.
Tongue Ratio
The ratio of the fin height to the gap distance between the fins
should be no more than 4:1. Higher ratios are possible but require an
indirect press which is uncommon in North America.
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Aluminum Alloy Options
Thousands of aluminum alloys have been developed. Profile produces primarily 6063
and 6061 alloys. We also extrude 1100, 3003, and 7075 from time to time.
Certain designs push the limits of what can be produced through extrusion. If your
ideal design poses challenges, we will openly communicate this and suggest
modifications to ensure compatibility with the aluminum extrusion process.
In many cases, designers are willing to make the necessary adjustments to ensure
successful extrusion. However, we understand that some projects may have low
probabilities of success. We approach such cases with transparency and work
together to explore alternative solutions.
Before going further, let’s consider the wide variety of applications of extruded
aluminum shapes and tubing:
• Disposable Medical Devices
• LED lighting system
• Stethoscope ear tubes
• Linear Slides
• Cooling systems for satellite electronics
• Aircraft Galley & Lavatory Hinges and Trim
• Medical Office Signage
• Bicycle wheels
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As you can see from the variety of projects above, aluminum extrusions are used
extensively in many industries. If you have an extrusion idea, the best way to
proceed is to ask the experts.
Call and describe what you’d like to create. For simple shapes like round tubes or
square bars, a simple description will be enough. For example: “I would like a quote
on 100 pieces of a 1.00” OD tube x .065” wall thickness x 144” long.” For a little more
complicated geometry, sketch a design on a piece of paper, scan it, and email it. For
complicated designs, it is helpful to provide a CAD file.
At Profile Precision Extrusions, we’ve reviewed thousands of designs to determine if
they are a good fit for the extrusion process. Sometimes the idea fits the extrusion
process but doesn’t fit our equipment. If that’s the case, we’ll be happy to suggest a
couple of companies in our industry that we think might be able to help. Our hope is
that your project becomes successful and you’ll remember us the next time you have an
extrusion project.
Some designs fit our capabilities but may push the envelope of what is possible to
produce with the extrusion process. We’ll tell you upfront that your ideal design is
challenging, and then suggest changes which will make it more extrusion-friendly.
” In many cases, the designer is willing to make the necessary changes. In other cases,
they ask us to try even though the probability of success is low.
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• Coating Options
• Anodizing is an electro-chemical process that forms a durable, oxide coat on the
surface of aluminum extrusions. If durability is a crucial factor in the success of
your extruded aluminum tube or extruded shape, hard coat anodizing (Type III) is
often a great idea. Commercial anodizing (Type II) is a solid choice for industrial,
medical, and recreational applications. Aluminum bike rims, linear slides, and
handguards are good examples of anodized aluminum extrusions. The anodized
layer prevents oxidation and protects the aluminum from scratches.
• Chem film coating (aka Alodine or Iridite) is a process in which a chromate
coating is used to protect the aluminum from corrosion. Another benefit is the
coated aluminum still maintains conductivity when coated. Chem films are also
used to improve the adhesion of paints or primers. The coatings come in
RoHS-compliant options for non-industrial applications. RoHS-compliant
versions are clear after application, while non-RoHS versions impart a
yellowish hue.
• Wet and powder paints are also commonly applied to aluminum extrusions to
enhance their cosmetic appearance and protect the aluminum from the
elements or abrasion. With both types, particles of electrically charged paint
adhere to electrically grounded surfaces of the aluminum and are then heated
in an oven to fuse the paint into a smooth coating. Paints come in a wide
variety of architectural, UL-rated, and UV-resistant options.
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STEP 2
Finding the
Right Partner
You have an idea for an aluminum extrusion but
are not sure where to start. You can Google
“aluminum extrusions” and start visiting
websites and making calls. But before you take
that step, you may want to visit the Aluminum
Extruders Council website (www.aec.org) and
the Aluminum Association website
(www.aluminum.org). These two industry
organizations have a wealth of information
about aluminum and the extrusion process.
Once you are ready to look for an aluminum
extrusion producer, keep in mind there are
hundreds of choices in North America.
With all the choices, how do you narrow them down? First, look for mills close to
you. Second, look for one that has the right size equipment for your design. To do
that calculate the smallest circle that your design will fit into. That's called "circle
size". Some mills like PPE have a maximum circle size of 4", others don't produce
anything under 7". Third, make sure your potential supplier extrudes the alloy &
temper you desire.
Ask the following:
1. What types of aluminum extrusions is your
company really good at producing?
Aluminum extrusion companies generally serve many different industries. Some
extruders focus on aluminum extrusions for the automotive market, and others focus
on the aerospace market. Ideally, you’ll want to choose a supplier that knows your
industry well.
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Also, be sure to look for indications of the sizes of a company’s typical extrusions. For
example, PPE specializes in custom miniature aluminum extrusions, with our
maximum tube diameter being 2.75”. If a customer needs larger parts, we wouldn’t be
the right fit for them. This is good to know early, as going to a supplier who
specializes in the types of parts you want will save both parties time.
2. Do you have a minimum order size?
Some mills require you to purchase a minimum of 500 or 1000 pounds of extrusion.
At PPE, we do not have a minimum order size.
3. Do I have to buy a die? And if I do buy an extrusion die,
who owns it?
Many aluminum extrusion companies have extrusion dies to make structural angles,
tees, channels, and round tubes. These are generally open for use by any customer. If
a standard extrusion will not work for you, you will have to purchase one. Be sure to
ask who owns the die and also ask if they provide free samples if you purchase a die.
Some companies have a policy that they own the tool you buy.
4. How do you support new product development? Do you supply
a first article inspection report at no charge? Do you ship
samples for approval ahead of running production orders?
If a new design you have in mind is outside a vendor’s manufacturing limits, ask
whether they suggest other mills that might be able to produce the design. New
product development and innovation is key to success.
5. Will you machine, anodize, or paint my extrusion?
In most cases, simplifying your supply chain makes sense. You save time by managing
a smaller vendor base, you save money by having fewer vendors marking up your
components and you also tend to have better quality because the parts pass through
fewer hands.
6. What was your on-time delivery percentage last month?
Last year?
In most cases, simplifying your supply chain makes sense. You save time by managing
a smaller vendor base, you save money by having fewer vendors marking up your
components and you also tend to have better quality because the parts pass through
fewer hands.
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7. How do you ensure precision in your work?
Higher precision equals less variation. For the machinist, less variation in the raw
material means less money spent on setups. It also means higher productivity when
machining a production order. For the assembler, less variation means spending less
time putting parts together. For the end user, less variation means the device runs
longer and is less prone to breakdown. The best mills in the industry understand that
minimizing variation is a measure of quality. Being precise matters so much, it’s in
our name!
8. Ask for references!
Ask other customers if the mill fulfilled the promises they made. Ask what, if
anything, the mill could improve upon. Find out if the reference would be willing to
work with the mill on a new project.
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STEP 3
Final
Design Quote
Additional research may be required to
finalize your design. You may be asked to
research alloy/temper options and determine
the best one for your application. The same
may be true for aluminum coatings. Your mill
can suggest options, but you will have to
make the final determination of what works
best for you. Patience may also be required if
you ask the mill to perform a process that
they typically don’t perform. It can take five
to ten business days to research your request
and find a possible vendor.
The following information will help you
obtain accurate pricing for your project:
• Design
▪ Ideally a CAD model
▪ A PDF file showing critical
features, surfaces and
dimensional tolerances
• Alloy & temper selection
• Cosmetic surface identification
• Coating requirements (if any)
• Packaging requirements (if any)
• Machining requirements (if any)
• End use
• Quality standard
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At Profile Precision Extrusions, our sales team will review your initial information
once it’s in our hands. For simple designs, you may have our quote within 24 hours.
For more complex designs, the sales team may ask you additional questions.
Once Sales determine they have enough information, they will review your design
with our production team. They will discuss the difficulty of the design, taking into
consideration the alloy and temper desired. If you would like your extrusion
machined or surface coating applied, they will also review those requirements. They
may even elect to show your design to one of our tooling vendors for feedback.
Complex designs may take up to four days to quote.
After you receive your quote, you may have questions, especially if exceptions to
your design have been taken. Don’t be afraid to ask for clarification. The last thing
anyone wants at this stage is miscommunication which becomes a bigger issue when
your order is produced. If working out the details takes two to three weeks, the lead
time quoted you may change. The mill and its vendors are accepting orders every
day, and it’s not unusual for lead times to flex in or out.
Aluminum extrusion project lead times can
vary based on the complexity of value-added
steps. For instance, a straightforward order that
involves only extrusion and shipping can be
completed in as little as three weeks. However,
additional processes like cutting, machining or
anodizing take additional time. For example,
cutting each piece to a specific length can add
an extra week, while anodizing those pieces
might extend the lead time by another two
weeks. These steps are essential for customizing
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aluminum extrusions to meet specific project requirements and should be factored
into your project timeline. PPE will be sure that you understand the lead time for
your project prior to placing an order.
It’s important to note that in-house capabilities can reduce lead times. At PPE, we’ve
added new, value-added equipment like precision saws, CNC machining centers,
wire EDMs, robotic arms, and inspection cameras to meet current and future
customer demand. Additional machining centers, double-end deburring, and pad
printing equipment are also planned. Bringing this type of work in-house typically
reduces the lead time by over 50%! Continuous investments in equipment and
facilities have allowed us to maintain relatively consistent lead times over the years,
even when demand surges across different industries.
Delivering quality aluminum extrusions in a timely manner is essential. Our team is
equipped to manage tooling lead times efficiently, ensuring that the production
process gets underway promptly. We also focus on minimizing your aluminum
extrusion project lead times by optimizing each step of the process and performing
as much of the work in-house as possible.
Moreover, PPE’s commitment to customer satisfaction is evident in our flexibility.
While we already offer shorter lead times than many in the industry, we are open to
considering specific timeframes for customers with urgent needs. This ensures that
customers get their aluminum extrusions precisely when they need them, without
unnecessary delays.
When you’re ready to place an order, there are likely administrative items that need
to be performed including new vendor surveys, credit applications, W-9s, etc. Profile
will create a 3D model of your design for the tooling maker and send it to you for
approval. After you approve the die print and the administrative details are
completed, the die will be ordered.
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STEP 4
Financial
Considerations
The cost to produce an extrusion depends on a
number of factors. The most important are:
• The amount of aluminum in the design.
• The alloy & temper - some aluminum alloys
extrude faster than others and will be less
expensive to produce.
• Dimensional tolerances required - in general,
the less variation allowed in the design
requires the mill to either slow down
production or scrap more of what they
produce. In either case, the cost of the finished parts will reflect that additional cost.
• Fabrication required - drilling a single .250” diameter hole in a part will be less
expensive than drilling 10 holes in that same part.
• Finishing required - anodizing or chem film coating extrusions are less expensive
than polishing or brushing them prior to coating.
• Special packaging - standard shapes used for industrial purposes are typically
packed in a bundle with metal-to-metal contact. Medical or Aviation extrusions that
have a highly cosmetic finish usually require special boxes and packing that
eliminates any metal-to-metal contact. They cost more to package and the cost is
passed along to the customer.
• Order Quantity - The number of parts ordered has a large impact on the price. Many
mills have a minimum order size of 1,000 pounds.
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At Profile Precision Extrusions, we do not have a minimum order size. We’ll run one part
or one million. When a customer orders an extrusion die, we typically include 30 to 50
feet of sample extrusion to be used for prototyping by our customer.
In general, we charge the following for extrusion dies:
• Solid shape: starting at $850 depending upon the design.
▪ These dies are made from a single piece of steel and take 2 weeks to fabricate.
• Hollow tube or shape: starting at $1850.
▪ Tubular dies are made from two pieces of steel. One-half forms the outside of the
tube, the other half the inside. Hollow dies typically take 3 weeks to make.
• Special hollow: $5,000
▪ Very small round tube dies or designs with multiple voids require a significant
amount of time to fabricate and use special steels and coatings. In addition to the
high cost, they also take eight weeks to produce.
Profile Precision Extrusions asks new customers asking for payment terms to fill out a
credit application and supply business references. Your references are contacted by fax
or email and asked about your payment history and credit limit. References can take up
to a week to respond, which slows down the evaluation process of our finance
department. We do not order tooling until credit is established or the customer has paid
for the tooling via check or credit card.
MILL TIP
Offer to pay for the extrusion die and samples with a credit card upfront. The die will be ordered up
to a week earlier than waiting for credit references to be contacted, reply and be evaluated.
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STEP 5
Framework of
the Project
The time it takes to quote a new extrusion
project is dependent upon its complexity.
A design of simple geometry that only requires
the part be extruded to length can be quoted
within 24 hours. A hollow design with complex
internal geometries and multiple fabrication
steps can take up to a week to quote. Once all
the details are worked out, the processing
timeline is straightforward.
After you place an order, your custom design is
translated into a Solidworks model drawing file.
The “die print” will be sent to you for review.
The objective is to make sure that all the information that has been discussed during the
quote phase of the project is captured. You’ll be asked to sign off on the die print that
all the details of the extrusion have been included. Once the print is approved, and
payment of the tool has been agreed upon, the die will be ordered.
The time to manufacture an extrusion die is generally three to four weeks. A solid die
with simple geometry (a round bar) takes three weeks. A hollow die (a round tube) takes
three weeks. The difference is the solid die is made of one piece of H13 tool steel. A
hollow extrusion is made from two separate pieces of tool steel. Those pieces are
fabricated individually. They have to match up perfectly to produce the hollow design.
Extremely complex multi-void hollows take up to ten weeks to fabricate.
Once the die is completed and delivered to the mill, it must be tested (die trial). The die
trial is a very short production run. Its objective is to determine if the die will produce all
the features & tolerances that the designer requires. The die is put into the extrusion
press and two or three billets are extruded.
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The extruded parts are rapidly cooled upon exiting the press, stretch straightened and
samples collected. The samples are then inspected by the quality department. If the
parts pass inspection, the extrusions are artificially aged to the final temper. The quality
department prepares a First Article Inspection report. After aging, the extrusions are
then cut to length, packaged, and shipped to the customer for approval.
MILL TIP
The die may not make good parts the first time. If that is the case, modifications may need to be
done to the die. In many instances, the modifications can be done in-house. They typically take two
to three days. In rare cases, the die must be returned to the die maker, which can take up to two
weeks to complete the required modifications.
At Profile Precision, our goal is to ship samples within three weeks of the die arrival. In
some instances, more than one trial is required. In those cases, the die must be cleaned
out, modified, and tried again. It generally takes an additional four or five days to
complete the second trial. In rare circumstances, the die must be returned to the die
maker for major modifications which can take up to two weeks.
Profile Precision will normally supply die trial samples with the purchase of an extrusion
tool. Generally, the quantity is between 20 and 40 feet of extrusion. Unless
arrangements are made in advance, the samples are for the extruded profile only.
Samples of fully fabricated parts can be ordered for an additional charge and
appropriate lead time.
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STEP 6
Finalizing Your
Creation
What happens once you finalize the design,
approve samples and have ordered extrusions for
a prototype run? As we mentioned above,
manufacturing always has some hiccups along
the way. If you find a problem with an extrusion
we’ve produced, let us know right away. An
email with photos can help. Even better is
sending a sample with what you’ve found.
Don’t hesitate to ask for help. We’ve taken
videos and photos for customers to share on
social media and post to crowdfunding sites.
We’ve had customers visit our plant to
understand the aluminum extrusion process
better. A plant tour is worth 1,000 words and costs nothing! We also have over twenty
sales representatives around the U.S. who are more than happy to lend their assistance
to your aluminum extrusion journey.
MILL TIP
If you want the extrusion order lead time expedited, give the mill a specific date you need the
samples rather than saying you “need it sooner.”
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STEP 7
Forging Ahead
with Production
Once the die trial samples have been approved,
your project is ready for the production phase.
For some projects, the die trial samples provide
enough extrusion for prototyping and
pre-production builds. For other projects, the
customer demand is for hundreds or thousands
of pieces. As a result, the lead time for
production volume is dependent on how busy
the mill you’re working with is, and the number
of process steps required to produce your parts.
You’ll want to keep in mind that most mills quote
you a ship date for your order, not a delivery
date. As a result, you’ll need to consider transit
time from the mill to you when calculating when you will receive your order.
Everyone is in a hurry these days. It’s essential to recognize that you’re not the only
project on the mill’s plate. In some cases, a mill may have 200-300 orders in various
stages of production. Asking for your order to jump to the front of the line is not
realistic. If you need to ask for your order to be expedited, communicate a specific,
realistic ship date based on the lead times you’ve been given. Your understanding of the
mill’s lead times and not “asking for the moon” can help build a strong relationship with
your chosen mill.
At Profile Precision our lead times to extrude “mill finish” orders are usually three to
four weeks. A good rule of thumb to determine the lead time to produce your order is to
add two weeks for each additional process. For example, if your parts need to be
extruded, cut to length, and anodized, the lead time would be: 4 + 2 + 2 = 8 weeks
in total.
Production hiccups in manufacturing are inevitable. Aluminum extrusions are no
different. It’s crucial to inquire about the “on-time” percentage of the mill you’re
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partnering with; anything above 90% is a positive sign. Common reasons for orders not
shipping on time include die repairs, quality control issues, delays by outside vendors, or
even the occasional hiccup with freight carriers.
During the production phase, you might find reasons to tweak your extrusion design.
Such modifications can be driven by factors like improved assembly productivity,
enhanced performance, increased strength, or lower cost. At PPE, we understand that
design evolution is a natural part of the process, and we are equipped to accommodate
these changes. Depending on the desired changes, existing extrusion dies may undergo
modifications at the mill or by the die maker. In some cases, a completely new die may
be necessary.
At Profile Precision, we consider a custom design to be proprietary to the customer.
We will not produce extrusions with that die for anyone other than the original
customer unless written permission is received by the original customer. When a
customer purchases an extrusion die, we will maintain, repair or replace it if necessary.
For projects that are ordered on a regular basis, we will also purchase backup tooling at
our expense.
In the complex world of aluminum extrusion production, choosing the right partner is
essential. Profile Precision Extrusion stands out as a partner dedicated to your project’s
success. We offer a deep understanding of production challenges, flexibility to
accommodate design changes, and a commitment to maintaining your extrusion die’s
integrity. Your project is not just another order to us; it’s a partnership for success.
MILL TIP
Choose your aluminum extrusion supplier carefully. Unlike other types of tooling, aluminum
extrusion dies generally are not easily transferable from one vendor to another.
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It’s likely that at some point early in the quoting process you would have been
introduced to the Sales Representative in your area. They live and work close to most of
our customers. They represent not only Profile Precision, but other manufacturers, and
are a wealth of information about manufacturing in your area. In addition to local Sales
Representatives, we also have two customer service locations. The first, in Kalamazoo,
Michigan serves many of our East Coast and Midwest customers. The second is located
in our Phoenix, Arizona production facility and serves our customers in the western U.S.
Contact us at 623-936-5599 any time to learn more, or get the
process started. We’re standing by to bring your aluminum
extrusion idea to life!
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Aluminum Advice
Common Aluminum Industry Terms
Aging - Thermal treatment of extrusions with the goal of changing its mechanical
properties to achieve the final temper.
Alloy - Aluminum is combined with small amounts of other metals to improve
characteristics such as strength, machinability, or heat transfer.
Billet - A cylindrical aluminum ingot that is forced through an extrusion die to
produce an extrusion.
Carbon Marks - Black lines on an extruded surface cased as the aluminum extrusion runs
out on the carbon block cooling table.
Circle Size - A description of the size of an extrusion-based upon the smallest circle
the profile will fit within.
Die Trial - A small production run to determine if an extrusion die is capable of
producing good parts.
Die Lines - Longitudinal lines on the surface of the extrusion. Typically caused by
buildup on the extrusion die surface.
Exit temperature - Target temperature for the extrudate prior to quenching. Proper exit
temperature helps to ensure the target mechanical properties are achieved.
ID - Inside Diameter
Log - A cylindrical length of cast aluminum ingot. (Logs are cut into shorter
lengths called billets prior to the extrusion cycle.)
Mill Finish - Describes the untreated surface finish or appearance of an extrusion.
Mill length - Refers to extrusions 144” long
OD - Outside diameter
Press Size - The size of the aluminum extrusion press is generally expressed in the
tonnage of force it produces or the diameter of billet it extrudes.
Quench - Cooling the extrusion from an elevated temperature
Screw boss - A circular feature with a 60-degree opening in an extrusion design which is
intended to accept a joining screw during an assembly operation
Temper - Describes the condition of the aluminum extrusion, typically in terms of
mechanical properties
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