Aluminum extrusion is a manufacturing process used to produce strong, lightweight components for applications such as aircraft, automobiles, high-rise buildings, conveyors, and generators.
This process is also used to produce bi-metal and multi-piece aluminum components. During extrusion, the material is forced through a die, often requiring multiple stages to achieve the desired shape and dimensions. The final product is typically heat-treated for enhanced strength, durability, and performance.
The Steps of the Aluminum Extrusion Process
The Process
In this case, a heated aluminum billet is forced through a custom die using an extrusion press, producing consistent, complex profiles.
Aluminum extrusion works much like shaping clay—material is pushed through a die to create a precise form.
The final product’s strength, finish, and dimensions depend on the alloy, temperature, and press size.
The Steps
1. Heat: Billets are heated to 800–900°F to make them pliable.
2. Lubricate: A lubricant is applied to prevent sticking during extrusion.
4. Cool: The extrusion exits hot (930–950°F) and is cooled with air.
5. Straighten: The material is cut and stretched to ensure alignment.
6. Finish: Final cuts are made, and the aluminum is aged to increase strength.
- Direct extrusion is the more traditional form of the process. It involves using a stationary die that the aluminum is then forced through by the pressure of a ram.
- Indirect extrusion is the opposite. In this case it is held stationary. The die is directly applied to the press at the end of the ram while the die moves against the billet.
While both processes can be used for various castings and products, the direct method is the most common. While the indirect method does have some advantages, it results in smaller profile products, and the process does not require friction, meaning the surface might be affected.
Custom Aluminum Extrusion Products
Extrusion allows for the production of several unique products. Some popular product options include:
- Safety fencing and guarding: If your factory uses moving machinery or machines that can result in flying debris, machine guards are essential. These tools protect workers from injury.
- Enclosures and rooms: From machine, laser, CCM, or clean rooms enclosures. Get more out of your space while also providing an isolated environment for testing and other critically sensitive operations.
- Workstations: From lift stations, fixture stations to manual assembly, workstations provide specific locations for various tasks.
- Material handling: Custom carts, lifts, supports, and conveyors provide your business with various material handling options.
- Component stands: Transformers, valve packs, and controllers often require unique mounting solutions. We design stands to specific weight capacities and requirements.
- Machine bases: Bases can come in heavy, medium, or light-duty options. You can review standard options or talk to a specialist about custom options.
- Work carts: From turnkey assembly carts to workflow carts, aluminum extrusion can produce carts to your exact specifications. Let’s create a cart that addresses all of your work and storage needs.
Why C&C for Aluminum Extrusion
C&C Manufacturing is an extrusion manufacturer specializing in various extruded products and services.
Since its founding in 2004, as one of the leading aluminum fabrication manufacturers, C&C has built a reputation for delivering reliable, high-quality solutions—from cleanroom enclosures, machine bases, machine guards, work stations, conveyors, racks, and various other custom designs. Including having worked with companies like Tesla, Toyota, Boeing, and Ford.
Whatever your project needs, C&C is here for you and your fabrication needs.