Created as a tool that will lead you through the decision-making process, the Extrusion Design and Performance Reliance Guide is an interactive step-by-step process illustrating the relationship between a series of design considerations for the most commonly used 6xxx-alloy profiles. See a more detailed explanation below.

Why use aluminum extrusions?

Aluminum extrusion's versatility unlocks the potential for countless applications and design options.The winning combination of aluminum's valuable, inherent characteristics and the advantages of the extrusion process make aluminum extrusions the material of choice for many designers and materials specifiers. Together, the material (aluminum) and the process (extrusion) offer advantages and their own set of considerations in the design process.

Aluminum Extrusion Design Parameters

Among the main factors influencing aluminum extrusion design decisions are: proper alloy, desired profile configuration, profile diameter, dimensional tolerances, and surface finish. Driven by end-use application within its specific market sector, the aluminum alloy's unique properties combined with extrusion process variables can influence these design decisions. The most commonly used extrusion alloys with good extrudability. strength. corrosion resistance. machinability. weldability. and formability are the 6xxx-alloy class.

What process variables influence product characteristics for 6xxx alloys?

To help clarify and open communication between extruders and their customer, a series of design considerations for the most commonly used 6xxx-alloy profiles has been created. Follow the three easy steps in the guide below to assist you with the decision-making process.

Extrusion Design and Performance Reliance Guide

Design Advantages

Extruded aluminum's adaptability accommodates both form and function economically.

•  Various alloys can be readily formed into complex shapes
•  Extrusion tooling is inexpensive
•  Lead times for custom shapes or prototypes are relatively brief
•  Many different finishes are available
•  Recyclability maximizes the life cycle value of the product

Aluminum profiles can provide the solution to many design challenges, including tight dimensional tolerances. Integrity is maintained as assembly or joining may not be required, however complex the cross-section may be. Should the need arise, aluminum profiles can be joined by all major methods in use today, including snap-fitting together with other extruded parts.

For a more detailed look at design considerations and material specifications, see the Aluminum Extrusion Manual, available for purchase in the Publications section of this website.