Email: info@processdevelopment.co.uk
Aluminium extrusions
The Process
Manufacturing of aluminium extrusions requires large powerful extrusion presses and dies to achieve intricate shapes.
The process by which a cut to length billet of aluminium alloy material is forced through a multiple stage die with a specific cross-section and shape. This billet is pushed with a great force of up to 5000 tons depending on the size of the press to achieve the final product. The powerful ram pushes the aluminium through the die and it emerges in the shape the die was constructed. It is then stretched on the runout table to achieve straightness and eventually cut to the required length. The remaining scrap is then recycled to produce the billet.
The process is similar to extruding chewing gum or plastic extrusions, where the die determines the shape and profile of the end product.
On the left, there are several examples of some intricate extruded shapes.
The use of aluminium extrusion in product design and manufacturing has increased significantly in recent decades and is being used in the automotive, aerospace, rail, construction, medical and food industries to name a few.
We can provide any type of aluminium extrusion from our reputable manufacturers at very competitive prices
Aluminium extrusion Fabrication
We provide a complete solution for the fabrication and machining of aluminium extrusions. There several methods to process extrusions to produce final products:
- Use of power presses and punching dies
- CNC machining
- Our own laser cutting and sawing
1. Power Presses and punching dies
These work very well where the shape of the extrusion is simple and easy to punch but cannot be used on extrusions that have intricate shapes with webs and require precise cutting without causing any dents or burrs. The process can take longer than required and the cost of manufacturing the punching dies can be extortionate. Lubrication is also required during the punching process leading to contamination of the profiles.
2. CNC Machining
CNC machining of aluminium extrusions is an expensive and slow process, however it is ideal where precision and finish of cut are crucial. Again, this is an expensive process and requires jigs and fixtures for productionized parts. With new technologies of dry milling, extrusions can be machined oil free. Talk to us if this crucial for your products. Again, jigs and fixtures can take 2 to 4 weeks to manufacture and this can result in long lead times for delivery of parts. We are experts at supplying parts for the BIW for Electric vehicles and all types of EV battery trays.
3. Laser cutting coupled with sawing
This is the fastest and accurate way to produce parts without waiting for punching dies or fixtures. The setup on the laser is simple with our 3D TubesPro software and any shape can be cut into the profile without worrying about special tooling or the profile orientation. However, laser cutting cannot be used to achieve surface machining or machining through the webs as it is ideal for outer surfaces. This is the reason, our 6KW fibre laser is coupled with a saw to cut any profile of the aluminium extrusion with internal webs, the laser cuts the geometries and the saw, cuts and mitres to length. We can supply parts for construction, medical, rail and food industry with minimum lead times.
You can read more about our laser cutting process in the tube laser section.
Send us your enquiry and we will recommend the best processing method for your parts.
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