The smallest aluminium profile we have manufactured measured approximately 4 mm × 4 mm and weighed 43 g/m. Small bespoke aluminium extrusions are possible, but the achievable dimensions depend on the profile geometry, wall thickness, alloy, tolerances, surrounding features, etc. We review each design individually to confirm whether it can be extruded reliably.
Design Assistance
Supporting Your Bespoke
Aluminium Profile Designs
Send us the drawings and specifications of your bespoke aluminium profile. We’ll review the complete manufacturing process from extrusion and machining to finishing, sub-assemblies, and packaging that would be necessary, and provide a quote back covering the entire production process, from the drawing to the delivery of your bespoke aluminium profile, ready for use.
Reviewing Your Aluminium Profile Design
We manage the entire manufacturing process, so when we review your aluminium profile design, we will consider every stage of production, including extrusion, machining, surface finishing, sub-assemblies, and packaging requirements.
We'll always look for the most efficient method to manufacture your profile, and since we manage the complete production of your bespoke aluminium profile, we will make sure that factors at one stage will not negatively impact another, like surface treatment influencing achievable machining tolerances or a feature in the extruded profile increasing machining complexity. We will suggest tweaks whenever we find ways to optimise production and reduce your costs (we've been able to help customers reduce their production costs by up to 50%), without affecting the performance of your final product.
You can explore more of our aluminium profile design recommendations as well as the standards we work with in our Designing with Aluminium Guide.
Designing with Aluminium: Complete Guide to
Bespoke Extruded & Machined Aluminium Profiles
Explore our design for manufacture guide covering aluminium properties, alloy selection (6xxx series), extrusion design rules, aluminium profile machining, anodising and other finishing services, and sub-assemblies and customised packaging for bespoke aluminium profile designs under European (EN) standards.
From Design to Delivery
Design Review
We review your bespoke aluminium profile drawings and specifications so see whether it is within our capacity, and we will provide a quote back if we can manufacture. Whilst reviewing your aluminium profile design, we will also be on the look out for any technical risks, unnecessary complexity, or opportunities to improve production efficiency.
Prototyping
Once the quotation has been agreed, we manufacture prototype parts for validation and testing. Prototype parts are typically delivered within 4 to 6 weeks, allowing you to test and refine your design before production launch.
Production Launch
Following prototype approval, we move into full-scale serial production, coordinating extrusion, machining, finishing, assembly, packaging, and logistics to deliver your aluminium component ready for installation or integration. Explore our bespoke aluminium extrusion and machining services.
Logistics
Typical production lead times range from 3 to 4 months. Regular deliveries arrive at our French headquarters every two weeks, allowing shipments to be split and scheduled according to your production needs.
Advantages of Working with ALUCAD
✓ Aluminium profile design reviews focused on manufacturing optimisation
✓ Expertise in both bespoke aluminium extrusion and aluminium profile machining
✓ Early identification of technical risks and production challenges
✓ Reduced manufacturing costs through design optimisation
✓ Rapid prototyping to validate your design before production
✓ Support from concept to serial production
✓ Design-for-manufacture advice for extrusion, machining, finishing, and packaging
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Send us your aluminium profile drawings and specifications
FREQUENTLY ASKED QUESTIONS
Questions About Bespoke Aluminium Profile Design
Yes. In fact, we will always recommend hollows over solid aluminium profile designs because hollows will not increases costs but they will decrease profile weight, which will bring about several benefits such as ease of handling. Find out more on hollow and solid aluminium profiles in our Designing with Aluminium guide.
Yes. We can help optimise your initial drawings so we can efficiently manufacture your bespoke aluminium profile and ensure we can deliver consistent and reliable results. This may involve slight changes in tolerances, or wall-thickness, sequence for machining, the operations to use to machine your profile, and more. Our suggestions will always be to improve the manufacture of your aluminium product, and generally, they also help reduce production costs.
All aluminium profiles we manufacture are bespoke to customer drawings. The components we produce are always both extruded and machined (we can also finish the part, but that isn't necessary). We rarely fabricate only extruded profiles. We have manufactured aluminium components used in the tranport, electronic and electrical, renewable energy, and buildings and construction industries. If you're not sure whether we're the right supplier for your bespoke aluminium profile, you can have a look at our Designing with Aluminium Guide for further information, or simply get in touch with us and ask.