When it comes to achieving precision, consistency, and efficiency in aluminium profile fabrication, choosing the right machining process is critical. While CNC machining is often seen as the go-to solution, it’s not always the most cost-effective or necessary route. Understanding the strengths of each machining method—and when to use them—can lead to better performance, lower costs, and more consistent results across production runs.
Understanding how machining works
Machining refers to the process of removing material from a workpiece to achieve a desired shape or finish. With aluminium profiles, machining typically follows extrusion and may include processes such as drilling, milling, cutting, tapping, and more.
CNC (Computer Numerical Control) machining is widely used due to its accuracy and repeatability. It’s ideal for complex geometries, tight tolerances, and detailed surface finishes. However, for profiles with straightforward features or high-volume orders, simpler methods can often achieve the same result more efficiently.
CNC machining: precision with a price
CNC machining is best suited for components that demand high dimensional accuracy, such as precision fittings, interlocking components, or parts with intricate contours. It's also a powerful tool during prototyping or low-volume production, where flexibility is essential.
But CNC comes with a higher cost per part—especially when the geometry doesn’t require such tight tolerances. It can also be slower when used for operations that could be automated with simpler tooling. That’s where knowing your profile's specific needs becomes essential.
When simpler solutions are smarter
Not every job requires the full capabilities of a CNC machine. For example, tapping—cutting threads into a hole—can often be done faster and more economically with manual or semi-automated machinery. The same applies to cut-to-length operations or standard slot milling, which can be performed with dedicated setups that reduce cycle time and increase throughput.
In high-volume production, a combination of custom jigs, multi-head drills, or rotary tables may outperform CNC in both speed and cost. It’s not about choosing the most advanced tool—it’s about choosing the right tool.
Optimising for repeatability and efficiency
The key to effective aluminium profile machining lies in developing a process that guarantees repeatability, efficiency, and waste reduction. That means balancing technical requirements with operational costs. At ALUCAD, we start by assessing the profile design, intended function, and production volume. From there, we identify the machining steps that ensure consistent quality while minimising time and overhead.
Sometimes, that means integrating CNC for key operations—like precision cuts or complex routing—and pairing it with manual or semi-automated processes for simpler features. This hybrid approach often delivers the best of both worlds.
At ALUCAD, we’ve worked with clients across industries to design efficient machining workflows tailored to each profile’s function and scale. Whether you're refining an existing part or developing something new, we’ll help you strike the perfect balance between precision, cost, and speed.