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Design Competition: For Professionals
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Professional Class

The winners of the 2016 International Aluminum Extrusion Design Competition were announced at the Eleventh International Aluminum Extrusion Technology Seminar & Exposition – ET ’16 in Chicago on May 6, 2016.

A total of $5,500 in professional prizes were awarded. The ET Foundation is grateful to Bonnell Aluminum for sponsoring the 2016 Design Competition.

The entries were judged by a panel of extrusion industry professionals, including David Asher, Process Optimization Manager for Bonnell Aluminum; Bill Rogers, VP Quality and Technology for Alcoa; and Todd Boyer, Director of New Business Development for Mid-States Aluminum.

View the 2016 Professional Design Competition winning entries

Endless possibilities...

For designers and engineers the possibilities are endless when designing with aluminum extrusions. Aluminum profiles can provide the solution to many design challenges. With aluminum extrusions you don't have to compromise your design to accommodate standard shapes, you can design exactly the shape you need and let the production process accommodate itself to your specific design.

Aluminum profiles have many advantages, including

  • Favorable strength-to-weight ratios
  • Flexibility of numerous alloys
  • Ability to design to close tolerances, and
  • Unsurpassed advantages of the extrusion process

...making aluminum extrusion the material and process of choice.

Careful design is the way to gain maximum benefit from the many variable characteristics of aluminum alloys and from the flexibility of the extrusion process. The Aluminum Extrusion Design Competition is a great place to show off your talent and innovation in design...and it offers the possibility of winning money and recognition for your unique design!

View previous winners

Aluminum Extrusion Design Resources

As you plan your design for the International Aluminum Extrusion Design Competition, visit the Design Resources page for some useful tips and links to helpful design and technical information.

Visit the Design Resources page

Judging Criteria

Winning entries will be those that demonstrate the benefits of aluminum extrusions, whether by inventing a new product or improving an existing one, by achieving the following objectives:

  • Creativity: innovative design, new application capability, methods to meet a new design challenge
  • Practicality: ease of fabrication and assembly, cost-effectiveness
  • Process improvement: customization or improvement of extrusion processes, close tolerances
  • Market Potential: design marketability and likelihood of market success.


Entry Categories

These are just a few of the possible applications for aluminum profiles. Submit your own design or prototype — it will be considered.

  • Office component systems
  • Exhibit display booths
  • Furniture
  • Architectural facades, windows
  • Bridges & bridge decking
  • Modular building systems
  • Satellite components

Photo courtesy of Classic Exhibits.

 Engineered Products
  • Bicycles, sporting goods, recreational equipment
  • Ladders, scaffolds
  • Lighting, lighting tracks
  • Appliances, other durable household goods
  • Scientific, agricultural, industrial, mining equipment
  • Machine components
  • Electrical & thermal components

  • Auto chassis & space frames, motorcycle frames & components, seat runners, roof rack rails, steering columns, door handles, radiator frames
  • Truck grills, trailer frames, flooring, cross members
  • Rail car frames & components
  • Airplane wings, seat tracks, window frames, handrails, landing gear
  • Space vehicle components
  • Boat hulls, crossbars, support bars, door & hatch cover trim, tracks & rub rails
Photos courtesy of Classic Trailers, Inc. and Aluminum Chambered Boats, Inc.

 Alternative Energy

Aluminum's sustainable characteristics, along with the versatility of the extrusion process, make aluminum extrusions ideal for alternative energy applications, including:

  • Photovoltaic and Concentrated Solar Power
  • Building-integrated photovoltaic modules
  • Wind power
  • Hydro-electric power
  • Geothermal energy systems

Any part or component designed for use in an alternative energy system will fit into this category.

Photo courtesy of Acciona

*The competition is not limited to the examples listed; these are just a few of the possible applications for aluminum profiles. Designs must be original and make use of at least one extruded aluminum component. Multiple entries may be entered. If any category yields no entries deemed by the judges to adequately address the competition’s criteria, a prize will not be awarded in that category.