Company Cases About What Are Aluminum Extrusion Profiles and How Are They Used
What Are Aluminum Extrusion Profiles and How Are They Used
2026-02-09
Aluminum extrusion profiles are special shapes made by pushing heated aluminum through a mold. You use these profiles to build strong frames, create precise machine parts, and design modern buildings. Their lightweight and corrosion resistance make them popular for both practical and decorative uses, such as curtain walls, modular frames, and custom features:
Application Type
Description
Curtain Walls and Building Façade
Add energy efficiency and style to buildings with slim, light structures.
Modular Structural Framing Solutions
Offer flexible and fast construction for many projects.
Custom Architectural Features
Help you create unique designs like sunshades and canopies.
You should learn about aluminum extrusion profiles because the market grows quickly, with values expected to reach over USD 176 billion by 2033.
The global market is projected to grow at rates between 7% and 8.4% per year.
Key Takeaways
Aluminum extrusion profiles are lightweight and strong, making them ideal for construction and manufacturing projects.
These profiles resist corrosion, ensuring long-lasting performance in various environments, including outdoor settings.
You can customize aluminum profiles in shape, size, and finish, allowing for unique designs tailored to specific needs.
The extrusion process is energy-efficient and supports sustainability, as aluminum can be recycled multiple times without losing quality.
Using aluminum profiles can enhance the aesthetic appeal of products while improving assembly efficiency in various applications.
Aluminum Extrusion Profiles Overview
Definition
You can describe aluminum extrusion profiles as shapes made by forcing aluminum through a special mold, called a die. This process creates long pieces with a consistent cross-section. You will find these profiles in many forms, such as solid bars, hollow tubes, and custom shapes. Each type serves a different purpose, from building strong frames to making lightweight parts.
Aluminum extrusion profiles stand out because you can customize them for almost any project. You choose the shape, size, and finish to match your needs. These profiles work well in construction, automotive, and electronics because they combine strength and flexibility.
Here is a table showing the main types and their characteristics:
Type
Characteristics
Applications
Solid
Offers strength and rigidity, suitable for structural applications.
Construction, automotive
Hollow
Lightweight and can be used for insulation or as structural elements.
Electronics, construction
Semi-hollow
Combines properties of solid and hollow, used for specific mechanical needs.
Various industrial applications
Specialty
Custom shapes for unique applications, tailored to specific requirements.
Specialized manufacturing processes
Key Properties
You benefit from several key properties when you use aluminum extrusion profiles:
Lightweight: Aluminum profiles weigh much less than steel. The density is about 2.7 g/cm³, so you can move and install them easily.
Corrosion Resistance: Aluminum forms a natural oxide layer. This protects the profiles from rust, making them ideal for outdoor and humid environments.
Strength: You can choose different alloy grades for your profiles. For example, 6061 alloy gives you high strength and hardness, while 6063 offers medium strength. Here is a table showing the strength of common alloys:
Alloy Series/Grade
Tensile Strength (MPa)
Yield Strength (MPa)
Strength Category
6063
190
145
Medium Strength
6061
310
276
High Strength and Hardness
1000 Series
Low
N/A
Low Mechanical Strength
Flexibility: You can shape aluminum extrusion profiles into almost any design. This lets you create frames, supports, and decorative features.
Customizable: You select the size, shape, and finish to fit your project. This makes aluminum extrusion profiles suitable for many industries.
Aluminum's strength-to-weight ratio gives you an advantage over steel. Steel is stronger, but aluminum's lighter weight lets you build structures that perform better for the same weight. You get strong support without adding extra mass.
Tip: When you need a material that is easy to handle, strong, and resistant to corrosion, aluminum extrusion profiles offer a smart solution.
Extrusion Process
How Profiles Are Made
You create aluminum extrusion profiles through a step-by-step process that shapes raw aluminum into useful forms. Here is how the process works:
Prepare the aluminum billet.
Heat the billet until it becomes soft.
Move the billet to the extrusion press.
Apply pressure to push the billet into a container.
Force the aluminum through a die to form the profile.
Guide the new profile along a runout table and cool it quickly.
Shear the profile to the right length for handling.
Let the profile cool to room temperature.
Stretch the profile to make it straight.
Cut the profile to the final size you need.
This process lets you create long, uniform shapes with precise details. You can make both simple and complex designs.
Aluminum extrusion stands out for its sustainability. You use less energy than with some other metal forming methods. Aluminum can also be recycled many times without losing quality. Here is a comparison of energy use and carbon emissions:
Material
Energy Consumption (kWh/ton)
CO₂ Emissions (kg/ton)
Aluminum
19,500
34,000
Steel
15,000
26,000
Materials and Tools
You need the right materials and tools to make strong and reliable profiles. Different aluminum alloys give you different strengths and uses. Here is a table showing common alloys:
Alloy
Tensile Strength
Strengths
Weaknesses
Applications
2024
455–483 MPa
Great strength, good formability
Poor corrosion resistance, poor weldability
Aircraft, gears, pistons
3003
110–200 MPa
Great formability, good corrosion resistance
Low strength
Fuel tanks, heat exchangers
5052
193–290 MPa
Great formability, great corrosion resistance
Poor machinability
Marine equipment, appliances
6005
170–270 MPa
Great weldability, good corrosion resistance
Average machinability
Furniture, rail cars
6061
241–310 MPa
Great weldability, good machinability
Average formability
Building products, bikes
6063
186–290 MPa
Great weldability, good formability
Average machinability
Window frames, sports equipment
7075
228–572 MPa
Great strength
Poor formability, poor weldability
Aircraft, gears
You also use special tools and dies to shape the aluminum. Here are some of the main tools:
Tool/Die Type
Description
Feeder
Controls the flow of aluminum for even shaping.
Die
Shapes the final profile as aluminum passes through.
Backer
Supports the die and acts as a heat barrier.
Hollow Die
Makes profiles with hollow sections using extra parts.
Semi-Hollow Die
Combines solid and hollow shapes for special designs.
Support Tooling
Keeps everything aligned and spreads pressure.
Press Tooling
Controls temperature and pushes aluminum through the die.
You can see that the right combination of materials and tools helps you create aluminum extrusion profiles for many uses.
Types of Aluminum Extrusion Profiles
Standard Shapes
You can choose from many standard shapes when working with aluminum extrusion profiles. Each shape serves a different purpose. Here are some of the most common options:
Hollow beam profiles help you build strong yet lightweight frames.
Triangular single radius profiles add support in corners and unique spaces.
L-shaped profiles give you strength for brackets and edge protection.
Aluminum angle profiles work well for joining and reinforcing structures.
Channel extrusions let you create tracks and guides for sliding parts.
Flat bar profiles offer simple support for panels and covers.
I beam profiles provide high strength for load-bearing projects.
T bar profiles help you connect different sections easily.
Framing profiles make it simple to build modular systems.
Trim profiles finish edges and add a clean look.
Tip: You can mix and match these shapes to build almost anything, from machine frames to display racks.
Custom Designs
Sometimes, your project needs a special shape or feature. You can design custom aluminum extrusion profiles to fit your exact needs. Here is what you should consider:
Material selection helps you pick the right alloy for strength or weight.
Profile design lets you create unique shapes for your application.
Tolerances ensure each piece fits perfectly.
Finishing options add color or extra protection.
Assembly integration makes it easy to connect parts during construction.
You see custom profiles in industries like automotive, aerospace, medical, electronics, and architecture. These designs help you solve problems such as reducing weight, improving strength, managing heat, or creating a unique look.
Surface Finishes
You can choose from several popular surface finishes to improve both the look and performance of your profiles. Each finish offers its own benefits:
Finish Type
Benefits
Brushing/Sandblasting
Creates a textured look, adds interest, and provides a matte finish.
Painting
Offers a bespoke look, color matching, and various finishes from glossy to matte.
Anodizing
Enhances corrosion resistance, provides a decorative finish, and allows for vibrant colors.
Powder Coating
Offers a wide variety of colors, good outdoor durability, and high resistance to abrasions.
Mechanical Finishes
Improves surface quality and prepares aluminum for cosmetic finishes.
You can pick a finish that matches your project’s needs. Some finishes make your profiles last longer outdoors. Others give you more color choices or a special texture.
Uses of Aluminum Extrusion Profiles
Aluminum extrusion profiles help you build, move, automate, and design many things you use every day. You see them in buildings, cars, factories, and even in your home electronics. Here is how you use these profiles in different industries.
Construction & Architecture
You find aluminum extrusion profiles in almost every modern building. The construction and architecture industry uses more than half of all extruded aluminum profiles worldwide. In 2024, this industry holds about 61.4% of the market. Experts expect it to keep a strong share, reaching 34.9% by 2025. Builders choose these profiles for their versatility and good looks.
Here is a table showing where you use them in buildings:
Your message must be between 20-3,000 characters!
