Aluminum Extrusion Services
Weldo produces custom aluminum profiles with die development, extrusion, heat treatment, cutting, CNC machining and surface finishing coordinated around your drawing and production demand.
*Alloy availability, wall thickness, width, tolerance and straightness depend on profile geometry, temper, die design and production quantity.
How Aluminum Extrusion Works
A heated aluminum billet is forced through a shaped die to create a continuous profile. The profile is then cooled, stretched, cut and aged before machining or finishing.
Direct Extrusion
The billet moves toward a stationary die. It is widely used and supports a broad range of profile geometries.
Indirect Extrusion
The die moves toward the billet, reducing billet-container friction and potentially improving uniformity.
Aluminum Alloys for Extrusion
Choose the alloy by strength, corrosion resistance, conductivity, finish, and profile complexity.
| Alloy | Material Characteristics | Applications |
|---|---|---|
| 5083 | Excellent seawater corrosion resistance and weldability; extrusion geometry requires review. | Marine structures, transport components, and corrosion-resistant profiles. |
| 6005 | Medium-to-high strength with good extrudability and structural performance. | Frames, ladders, platforms, and transport structures. |
| 6061 | Balanced strength, corrosion resistance, weldability, and machinability. | Machine frames, structural profiles, and CNC-finished components. |
| 6063 | Excellent extrudability and anodized surface quality with moderate strength. | Architectural profiles, enclosures, trim, and heat sinks. |
| 6082 | Higher-strength 6xxx alloy with good corrosion resistance and weldability. | Bridges, scaffolding, transport, and heavy structural profiles. |
| 6101 | High electrical conductivity with useful strength and extrusion performance. | Busbars, electrical conductors, and power-distribution profiles. |
| 7003 | High strength, good weldability, and better extrusion response than many 7xxx alloys. | Automotive structures, bicycle frames, and impact-resistant profiles. |
| 7108 | Very high strength and energy absorption for demanding structural extrusions. | Crash-management systems and high-strength vehicle structures. |
Surface Finishes for Extruded Profiles
Surface treatment protects aluminum profiles from corrosion, wear, ultraviolet exposure and weathering while controlling color, gloss, texture and cleanability. The right process depends on the service environment, appearance standard, profile geometry and budget.
Ceramic Coating / MAO
Creates a ceramic-like oxide layer for high wear and corrosion resistance. Used for demanding industrial and decorative profiles.
Anodizing
Forms a hard aluminum-oxide layer that improves corrosion resistance, wear behavior and color stability. Used for frames, architecture and electronics.
Electrophoretic Coating
Deposits a uniform resin film that covers edges and recesses, improving gloss and corrosion resistance. Used for premium doors, windows and appliance trim.
Powder Coating
Electrostatically applies and heat-cures a durable colored coating. Used for architectural profiles, furniture, housings and indoor decoration.
PVDF Coating
Applies a highly weather-resistant fluorocarbon coating with strong UV and color retention. Used for curtain walls, coastal buildings and severe outdoor exposure.
Aluminum Extrusion Capabilities
Capability is confirmed from alloy, profile envelope, wall distribution, tolerances, temper, quantity and finishing requirements.
| Billet diameter | 100–500 mm reference |
| Billet length | 1–7 m reference |
| Maximum profile width | Up to 1100 mm |
| Minimum wall thickness | About 0.8 mm |
| Length precision reference | About ±0.05 mm at 5 m, subject to geometry review |
| Coarse-grain ring depth | ≤0.3 mm reference |
| Straightness | About ≤0.3 mm/m |
Custom Die
Die design is matched to alloy flow, wall balance and profile complexity.
Cut to Length
Profiles can be supplied in production lengths or cut for downstream use.
CNC Machining
Drilling, milling, tapping and precision end features can be added.
Finished Profiles
Heat treatment, straightening, anodizing, coating and inspection can be integrated.
Aluminum Extrusion Design Guidelines
Stable profiles begin with alloy-appropriate temperatures, balanced metal flow and geometry designed for extrusion and downstream finishing.
Balanced Walls
Keep adjacent wall thicknesses reasonably consistent to improve metal flow and cooling.
Soft Transitions
Use radii and gradual thickness changes instead of sharp internal corners.
Symmetrical Geometry
Balanced profiles generally extrude and straighten more consistently.
Support Thin Features
Add ribs or local support where long thin walls may twist or distort.
Machining Allowance
Reserve material where critical holes, threads or sealing faces will be machined.
Finish Allowance
Account for anodizing or coating thickness at fits and assembly interfaces.
Advantages and Applications
Aluminum extrusion creates lightweight continuous profiles with integrated channels, ribs and mounting features, reducing later material removal and assembly.
Construction
Door, window and curtain-wall profiles requiring appearance and corrosion resistance.
Transportation
Lightweight vehicle, rail and structural profiles with secondary machining.
Electronics
Heat sinks, housings and support profiles for thermal management.
Machinery
Machine frames, guides, guards and modular automation structures.
Furniture
Lightweight frames, tracks and decorative architectural components.
Renewable Energy
Solar-panel frames and corrosion-resistant support structures.
Frequently Asked Questions
Concise guidance on alloy selection, profile length, thin walls, surface quality and quote preparation.
How should surface bubbling be addressed?
Review billet homogenization, die venting, contamination, billet temperature and extrusion speed before changing one parameter in isolation.
Should I choose 6061 or 6063?
Choose 6061 for higher structural strength and machining; choose 6063 for easier extrusion and superior architectural or anodized appearance.
What limits the maximum profile length?
Press runout, handling equipment, profile stiffness, heat treatment, straightening and shipping constraints all affect practical length.
How is thin-wall deformation controlled?
Use balanced geometry, suitable alloy and temper, controlled cooling, stretching and straightness inspection.
When is extrusion economical?
Extrusion is strongest for repeat quantities where die cost is distributed across continuous profile production.
What files are needed for a quote?
Send STEP or CAD profile data plus a dimensioned drawing, alloy, temper, length, quantity, finish and critical tolerances.
Start Your Aluminum Extrusion Project
Upload the profile drawing and identify the alloy, temper, cut length, quantity, surface finish and critical tolerances.
Upload Extrusion Files