Many bespoke aluminium profiles require machining to meet final specifications. It might mean drilling threaded holes for assembly, machining precise slots, creating interlocking features, cutting to tight lengths, or finishing edges to meet visual standards.

Choosing the right combination depends on profile function, tolerances, and production volume. It is easy to default to CNC machining for your custom aluminium product, thinking it will deliver the best results. It has a strong reputation in aluminium profile machining for a reason.

But it isn’t always the best option.

When CNC machining is the right solution

CNC (Computer Numerical Control) machining is often the first thing engineers think of when they hear “aluminium profile machining.” It is, after all, the foundation of precision manufacturing.

If your custom aluminium product includes blind holes at controlled depths, complex contours, tight positional tolerances, or multiple features which must align perfectly across assemblies, CNC machining gives you that control. It works directly from CAD data so your digital design is translated into physical accuracy with exceptional repeatability.

CNC is ideal when you’re in prototype or low-volume production. There’s no need to invest in dedicated tooling upfront. You can move from design to machined part quickly, refine the geometry if needed, and maintain tight dimensional consistency throughout.

If precision and flexibility are your priorities, CNC is often the safest and most reliable option for bespoke aluminium profiles.

But it isn’t automatically the best solution for every custom aluminium machining project.

When punching is the better than CNC machining

If your profile requires high volumes of identical holes or repetitive features, punching systems can outperform CNC in both speed and cost efficiency. Each press stroke produces the same result, making repeatability extremely high. In thin sections especially, punching can eliminate the minor vibration effects sometimes associated with CNC drilling.

There’s also a production advantage. Once a custom punch tool or die is built, the per-part cost drops dramatically. For long production runs, the initial tooling investment reduces total machining costs significantly.

In some cases, punching can even deliver more consistent results for repetitive geometries, simply because the motion is controlled in a single, decisive action.

A case study where punching outperformed CNC

We are product-driven at ALUCAD, which means we will always aim to maximise client value and ensure the chosen machining process produces the best results for their custom aluminium product, and saves on cost.

We once had a client approach us with a design built entirely around CNC machining. On review, we noticed the critical features could be achieved more efficiently through a custom punching solution.

We developed a dedicated tool for our punch press made specifically for their bespoke aluminium profile. It required an upfront investment in tooling, but once implemented, machining time dropped substantially. The final delivered cost (including extrusion, machining, finishing, delivery—everything) was closer to what the client would've had to pay for material alone elsewhere. Choosing the right machining process for your aluminium profile plays a huge role in the overall costs.

Efficient aluminium profile machining

Efficient custom aluminium machining is not about one process over another. Every project is different. Some demand complex CNC work. Others benefit from a hybrid approach, combining CNC for critical features and punching for repetitive operations. Don’t start with a machining process in mind, start with the product. It’s about aligning geometry, tolerance requirements, alloy choice, and production volume with the manufacturing method that creates the best balance among precision, repeatability, and long-term cost control.

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Contact us if you’re developing custom aluminium products and want to ensure your aluminium profile machining is engineered for both performance and procurement efficiency.