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EDU '19 - Extrusion Design University
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EDU'19 - Extrusion Design University



EDU '19 Program

The EDU '19 program is packed with practical, valuable information about aluminum extrusion design, processes and applications. Top-notch speakers from some of the most knowledgeable aluminum industry companies will share their expertise on a wide variety of topics. Check back often as program details unfold. Note: Session schedule to be determined. AEC reserves the right to alter the program and substitute speakers as needed.

Regarding Professional Development Hour Credits for Engineers

If you are an engineer licensed in a state that pre-approves course providers or individual courses (such as Florida, New York, New Jersey, Maryland, Indiana, or North Carolina), we do not yet have pre-approved status in those states. However, if your state's licensing board does not pre-approve course providers (any other state besides those listed above), then it is the individual engineer’s responsibility to determine whether an activity meets their particular state board’s acceptance criteria.  AEC will provide you with an agenda, a certificate of attendance, or any other documentation (within reason) that your state board requires in order to consider approving the continuing education PDH credits at EDU '19. More information will be provided on-site at the event to ensure that you attended and can submit the PDH credit with your state licensing board.

AIA - Continuing Education


AEC is an approved provider through the American Institute of Architects (AIA). Courses that have been CES registered are noted below. Please check back often for updates.

Topic-Specific Tracks

Sessions will be presented in three topic-specific tracks (click on the track name to jump to the sessions):


Architecture/Building & Construction

Engineered Products/Industrial


Automotive Track

Specifying & Achieving Desired Extrusion Performance for Automotive Extrusions

Mark Butterfield, Managing Director, Magnode, A division of Shape Corp.

Since 2012, the usage of extruded aluminum shapes in North American light vehicles has grown by more than 50%, to over 25 pounds per vehicle. Today, aluminum extrusions can be found in applications as varied as crush cans, trim members, rocker sections and seat backs – each with a unique set of performance requirements. As automotive aluminum extrusion applications continue to grow, engineers seeking optimized performance are increasingly going beyond the “shorthand” of alloy and temper designation by specifying the desired microstructure for the final component. Mini cases will be used to illustrate successful application of microstructure specification.

At the end of this presentation, participants will be able to:

  1. Explain why various automotive applications require different underlying microstructure for optimal performance.
  2. Identify how alloy chemistry can be manipulated to yield distinctive microstructure.
  3. Identify how extrusion processing parameters can be manipulated to yield distinctive microstructure.
  4. Describe how to effectively specify microstructure and the critical variables to consider.

Aluminum Extrusion Alloys for Transportation Lightweighting Programs

Jerome Fourmann, Rio Tinto Aluminium

Engineered products using aluminum extrusions provides a number of options and solutions. This presentation will discuss how aluminum extrusion can help meet tomorrow’s fuel economy targets while providing the comfort, safety, and performance that consumers demand. A variety of alloys suited to transportation applications will be reviewed along with their characteristics, industry standards and performance impact.

Anodize for Auto and B&C Applications

George Oh, Houghton

Anodizing is an electrochemical process in which the surface of the aluminum is intentionally oxidized producing a porous oxide layer. This unique oside is decorative, durable and corrision resistant. Many markets, such as the architectural and automotive industries, use anodized aluminum. The speakers will discuss the basics of anodizing, highlighting the slight differences which should be considered when anodizing aluminum for automotive and  architectural industries.

Joining Aluminum Extrusions Through Friction Stir Welding

Jason Weber, VP Sales and Marketing; Taber Extrusions

Friction Stir Welding (FSW) is not a new technology and has been in use for decades. Although pioneered for the aerospace industry, recent advances in FSW machine design and FSW capacity continues to open the possibility for new products to be joined through FSW. This presentation will cover the basics of what FSW is, current products that are joined with friction stir welding, general design practices for extrusions incorporating FSW features, and typical performance of FSW joints versus other joining technologies.

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Architecture Track

Aluminum Extrusion Anodizing for B&C Applications: What You Should Know

Adam Stone, Process Engineer for Anodizing Process, Bonnell Aluminum

Attend this informative session to better understand the requirements deemed “critical to success” to anodizing for aluminum extrusions in building & construction applications. Understanding the differences between various anodizing types (Class I, II and III), clear versus 2-step, the relative strengths and weaknesses of each anodizing type, comparisons with AAMA 2603 and 2605 coatings, corrosion resistance and common types of corrosion, the effect of alloys and temper and the importance of die maintenance to achieve finish consistency. The cleaning and maintenance specifications (AAMA 609-610) required to maintain finish durability and testing requirements to ensure anodizing quality will be discussed.

At the end of this presentation, participants will be able to:

  1. List the different architectural classifications of anodized aluminum and electrolytic color.
  2. Explain the performance characteristics of the different types and classifications of anodized aluminum which are commonly available in architectural markets.
  3. Compare the advantages and disadvantages of anodic coatings to mill finish or painted aluminum finishes.
  4. Identify common requirements deemed “critical to success” to anodizing for aluminum extrusions in building and construction applications including profile design, alloy, temper, environmental, and maintenance of the finished product.

AIA - Continuing Education1.0 AIA LU Hour

High Performance Fluoropolymer Coatings

Scott Moffatt, Architectural Sales Manager-Building Products, PPG Industries

This course is designed to explain the differences in PVDF versus FEVE fluoropolymers resin systems. It also covers the type products available by explaining pigmentation used for durability, IR reflectivity and appearance options like solids, micas and metallics. There are different types of application methods for fluoropolymers and various qualities available in liquid and powder formulations. This course also provides performance overviews based on AAMA performance specifications.  

At the end of this presentation, participants will be able to:

  1. Explain fluoropolymers and their intended uses
  2. Discuss the different types of pigments used in Fluoropolymer coatings and list the different types of Fluoropolymer product options
  3. Describe the long term UV durability of fluoropolymers, which includes an overview on IR reflective Fluoropolymers
  4. Recite the performance expectations of these coatings related to AAMA specifications

AIA - Continuing Education1.0 AIA LU Hour

Designing High Performance Facades

Bill Blazek, Technoform

This course describes the multiple challenges in designing high performance building envelopes in order to deliver energy performance, sufficient glazed area for optimized daylight admission and views, thermal comfort and condensation resistance (indoor air quality) as well as structural and durability performance, yet still providing architectural design freedom. Common disconnects in specifying fenestration and fenestration components are reviewed. The concept of the “thermal zone” is introduced, and technologies such as polyamide thermal breaks and warm-edge spacer that improve its performance are described. Guidance is provided on choosing the optimum thermal break and edge of glass spacer technologies to meet thermal performance requirements while still delivering the structural and durability requirements, and also allowing architectural design freedom. The fenestration U-factor requirements of the recently updated and more stringent energy codes, and how to specify fenestration components to meet them, are also covered. 

At the end of this presentation, participants will be able to:

  1. Describe the current challenges for designing high performance, sustainable, building envelopes.
  2. Identify the common misconceptions regarding the specification of fenestration
  3. Summarize the key thermal zone technologies in the market and choose optimum thermal break and spacer technology to reach design thermal performance targets, while maintaining durability and structural performance, and optimizing aesthetics
  4. Identify through case studies the use of thermal zone technology selection strategies to create high-performance building envelopes in a range of climate zones and applications.

 AIA - Continuing Education1.0 AIA LU Hour

When to Use Storefront or Curtainwall

Chris Giovannielli, Kawneer

This course provides an overview of the differences between curtain wall and storefront designs and functions. System fabrication and installation, and water performance are also discussed. 

At the end of this course, participants will be able to:

  1. Explain what a Storefront System is and how is it best utilized in a commercial project
  2. Explain what a Curtain Wall System is and how is it best utilized in a commercial project
  3. Identify the primary drivers that must be considered when deciding between Storefront or Curtain Wall
  4. Describe the proper application of each system.

AIA - Continuing Education1.0 AIA LU Hour

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Engineered Products/Industrial Track

Utilization of Aluminum Extrusion in LED Fixtures

Rob Nelson, Almag Aluminum

Aluminum extrusions are present in a multitude of components that make up a light fixture in today’s lighting industry – and with very good reason. The recent advancement of extrusion technology, as well as the inherent properties of aluminum, make choosing aluminum extrusions as a light fixture component an easy choice. Aluminum has a high strength-to-weight ratio and great corrosion resistance, which make it great for light housings, as well as high thermal conductivity making it great for heatsinks. Aluminum extrusions are also soft enough to be formed prior to age hardening, yet hard enough to have good machinability afterwards. Knowing the limits of aluminum extrusions will help provide a better solution to light fixture designs.

At the end of this presentation, participants will be able to:

  1. Explain how to optimize geometry for heat dissipation.
  2. Compare the alloys to select for best performance results.
  3. Discuss how aluminum extrusions can be formed prior to age hardening.
  4. State how to apply design techniques to expand the limits of wall thickness and tongue ratios for optimum performance.

AIA - Continuing Education1.0 AIA LU Hour


Extrusion Design through Visual Applications

Rob Nelson, Almag Aluminum

Aluminum extrusions are used in all types of applications that support the Signage industry. Aluminum’s high strength to weight ratio and great corrosion resistance make it an optimal choice for frames and fixtures for visual displays. Whether the application is in an indoor retail space or harsh external environment Aluminum meets the challenge. In most cases the signage is not about the extrusion but about the advertisement and this presentation will explore fit form and function of a rapidly growing industry.

At the end of this presentation, participants will be able to:

  1. Describe finishing and fabrication techniques for aluminum extrusion.
  2. Discuss slide and snap fit mechanisms for ease of assembly.
  3. Assess alloy selection for controlling tolerances.
  4. Identify the different profile designs of aluminum extrusions.

AIA - Continuing Education1.0 AIA LU Hour


Fabrication: Adding Value to Aluminum Extrusions, When & How

Mark Butterfield, Magnode, A division of Shape Corp.

Over the last two decades extruders have extended their offerings to the marketplace in the way of fabricated aluminum extrusions. From precision cutting to CNC machining, extruders are adept at delivering a final part straight to your production line. However, the question is: where in the manufacturing continuum should you ask your supplier to deliver? This session will help you determine what options are available and how they can transform the way you make your products.

At the end of this presentation, participants will be able to:

  1. Identify the types of fabrication methods typically offered by aluminum extrusion manufacturers.
  2. Describe and compare value streams associated with fabricated components.
  3. Identify opportunities for optimization and the link between extrusion and fabrication.
  4. List cost drivers associated with secondary operations and methods to offset them.
  5. Compare new technologies and options for aluminum fabrication.

AIA - Continuing Education1.0 AIA LU Hour


Design Considerations for Cost Effective Extruded Products

Andrew Tomczyk, President, Erbsloeh Aluminum Solutions Inc. -WKW Extrusion

Target costing is a key element for success of any product, no matter the market. Often, target costs are missed and profitability suffers due to design concepts that are overlooked. This presentation will start with a top-down approach for effective design of extruded products.

Generally, raw material makes up 40% of the total cost of an extruded product. Focusing on aluminum as the lightweight material of choice, the speaker will discuss the most important factor for cost consideration, the weight of the part, by explaining how to optimize profile design for best weight and utilize Computer-aided Engineering (CAE) analysis for best structural performance with least material.

Additionally, value-added fabrication, such as CNC machining, punching, sawing, and drilling, contributes 25-30% cost to the product. The pure nature of extrusion as an engineering profile with extended length should direct designers to focus on the connection points of the extrusion. In the vast majority of cases, the connection points are the ends of the extrusion; 80% of the value-added costs are typically at the ends of the product—the connection points. CNC vs punching, as well as communizing radii for CNC milled features for cost-effectiveness will be discussed. A video of CNC milling that demonstrates many of the points mentioned above will be presented.

At the end of this presentation, participants will be able to:

  1. Describe the cost drivers for new product development for aluminum extrusions
  2. Discuss the utilization of engineering tools for effective extrusion design
  3. Identify the Design for Assembly (DFA) / Design for Manufacturing (DFM) considerations for aluminum extruded products
  4. Explain design considerations for CNC machining operations

AIA - Continuing Education1.0 AIA LU Hour

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