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Designing with Aluminum Extrusions - Webinars

AEC WebinarsAluminum extrusions offer an outstanding level of design flexibility, the ability to tailor component properties, cost-saving functionality and environmental benefits. Yet extrusions' almost limitless design possibilities present unique challenges to the designer and engineer:

  • How should extrusions be designed for minimal system cost and optimal manufacturing?
  • What are the do's and dont's in profile design?
  • How can shapes be optimized to meet structural requirements?
  • How can extrusion design impact the economics of extruded components vs. alternative materials?

The Aluminum Extruders Council offers webinars aimed at educating engineers and designers on the advantages of and practical considerations for designing with aluminum extrusions.


AEC has added a series of webinars aimed at designers, engineers and others who wish to delve deeper into the ins and outs of aluminum extrusion. The new series, AEC Aluminum Extrusion Tech, is intended to inform and educate those with some knowledge of aluminum extrusions but who are interested in a more technical focus. Look for this logo identifying these advanced-level webinars.

Upcoming Webinars

The Power of the Hollow: Using Hollow Aluminum Extrusions to Meet Vehicle Engineering Challenges
Automotive Extrusions Webinar
September 30, 2020
2:00 p.m. ET
Speaker: Mark Butterfield; Managing Director, MAGNODE – A Shape Corp. Company
Hosted by: SAE International

One of the attributes of aluminum extrusions that can provide both design flexibility and performance benefits for the automotive engineer is the ability to design profiles that "put the metal where it is needed". That's particularly advantageous when it comes to hollow shapes, particularly multi-void hollows which can be engineered for a combination of crush resistance, strength, light weight and more. This webinar will review some of the more interesting uses of multi-void hollows in today's vehicles, and discuss the alloy, design and processing considerations necessary to ensure success.

In addition, there will be a brief overview of AEC's new online educational tool for automotive designers that highlights the use of aluminum extrusions in various vehicle systems.


After the Press: Utilizing Downstream Fabrication to Create the Aluminum Extrusion-Based Solutions You Need
October 14, 2020
2:00 p.m. ET
Hosted by: Design World

With most aluminum extrusions, the long length of a desired shape that comes off the press is just a starting point. Rarely are these profiles used as they were extruded. In almost every case, there is subsequent cutting, drilling, milling, machining, bending, joining and/or finishing required to transform the extrusion into a component or sub-assembly for inclusion in a final product. This webinar will recap the fabrication processes typically employed, with an emphasis on extrusion design considerations that can reduce fabrication costs.


Aluminum Extrusions & High Performance Building Envelopes: Still the Answer
October 29, 2020
1:00 p.m. ET
Speakers: David Baresh, Sierra Aluminum and Barb Johnson, Hydro Aluminum Building Systems
Hosted by: Architect's Newspaper -AN

This program will explore the challenges in designing contemporary building envelopes. Potential conflicts in simultaneous objectives of achieving aesthetics, energy efficiency, sustainability, longevity, and occupant health and safety will be discussed. In addition, how best to assess the energy efficiency of alternative window/window wall configurations will be reviewed. Advances in thermal barrier materials and extrusion profile design – in conjunction with energy efficient glazing – will be shown, illustrating how these systems can provide window and curtain wall designs that meet or exceed more demanding energy codes while providing the daylighting and minimal sight lines that users and designers desire.

Upon completing this course, the learner will be able to:

  • Identify current challenges in designing high performance building envelopes
  • Assess alternative framing materials
  • Understand how contemporary thermal management technologies can meet increasingly demanding energy codes
  • Utilize aluminum-extrusion-based windows and curtain wall to meet often conflicting project requirements


AEC On-demand Webinars

  • November 2019: Creating Cost-Effective Extruded Aluminum Component Solutions
    Speaker: Andrew Tomczyk, Erbsloeh Aluminum Solutions, Inc. | Hosted by: Design News
    Cost is always an important consideration when developing or updating products. But how do you know if the lowest price component will lead to the most cost-effective solution …
  • November 2019: BEV or ICE: Aluminum Extrusions & Tomorrow's Vehicles
    Speaker: Ben Kuhn, Almag Aluminum | Hosted by: SAE International
    Regardless of the resolution of the current dispute over light vehicle fuel economy and carbon emission standards, the drive to reduce vehicle mass will continue.

  • May 2019: Aluminum Extrusion Dies: 7 Decisions that Increase Your Die Tooling Costs
    Speakers: Carl Meyerhoefer & Eric Becker, Vitex Extrusion
    This webinar provides a brief review of the aluminum extrusion process and then addresses seven factors that impact the cost of an extrusion die, including profile complexity, tolerance requirements, and alloy use. Extrusion die types and tips for driving down tooling costs are also covered.

  • December 2018: How Aluminum Extrusions Can Help Meet Product Challenges
    Speaker: Mark Telander, Alexandria Industries | Hosted by: Design News
    This webinar explores the unique attributes of the aluminum extrusion process and how they contribute to effective product solutions. It will also offer tips on designing and specifying extrusions to ensure the needed performance in a cost-effective manner. 
  • November 2018: Aluminum Extrusion Design Competition 2019

  • November 2018: Introduction to Extrusion Dies

    Speakers: Richard Dickson, Hydro Aluminum; Rick Liscomb, Exco Canada
    If you're interested in knowing more about how aluminum moves through a die to create a desired part, this webinar is for you. We will discuss die design and what makes a section difficult or easy to extrude. We'll also cover how specific extrusion artifacts–e.g. location of screw lugs and walls–affect surface properties. And we'll cover the flow of metal through the container to provide a better understanding of the challenges of die design, and how design impacts quality.
  • October 2018: Using Aluminum Extrusion to Meet the Challenges of Tomorrow's Vehicles
    Speakers: Rob Nelson & Ben Kuhn, Almag Aluminum | Hosted by SAE International
    This webinar reviews the thermomechanical extrusion process, as it is that process that drives component performance, and then explores how extrusions will play an important role in ongoing safety improvements and in vehicle electrification.

  • September 2018: Metal Flow Fundamentals
    Speaker: Jerome Fourmann, Rio Tinto Aluminium| Hosted by: AEC

    This webinar will cover the fundamentals of aluminum metal flow through the container and the die allowing a comprehensive understanding of the challenges in ensuring prescribed quality and part performance.  Particular attention will be paid to welds – both billet-to-billet and in the formation of hollow shapes – and to the challenges of wider profiles.  We will also review the press practices that can be the root causes of potential defects and how they are managed for various extrusion applications.  

This webinar covers the requirements it takes to achieve optimum properties for structural extrusions. Higher strength 6xxx alloys, such as 6005, 6061 and 6082 will be covered; however, the content will be broadly applicable for most 6000-series alloys. Technical issues for assuring properties and maintaining profile geometry for structural applications will be discussed.

View more archived webinars >>