Designing Bespoke Extruded Aluminium Products
for Efficient Manufacture

Practical guidance on alloys, extrusion, machining, and finishing under European EN standards.

1. About ALUCAD & Purpose of This Guide

ALUCAD specialises in the production and supply of custom extruded aluminum manufactured products intended for serial (mass) production. We operate across the full production chain, from early design support and aluminium extrusion through to surface finishing, in-house precision machining, assembly, packaging, and ongoing quality control. This end-to-end involvement gives us direct visibility into how design decisions translate into real manufacturing outcomes.

Founded in 2000 by CEO Laurent Hendrickx, ALUCAD is a French company headquartered in Argentan, France, with its production centre located in Foshan, China. We operate to European standards, with engineering oversight, quality requirements, and specifications defined in line with EN norms. This structure allows us to combine European design discipline and standards compliance with efficient, cost-effective manufacturing.

Our technical team in China has an average tenure of ten years, and our factory manager has been with ALUCAD for over seventeen years. The production site was created “ex nihilo” by Laurent Hendrickx, who spent twenty years on site to ensure that processes, quality expectations, and working practices were fully aligned with ALUCAD’s values and European standards.

Why this guide exists

In practice, many issues with aluminium profiles do not arise from production capability, but from design assumptions made early in a project without full awareness of manufacturing constraints.

Typical examples include:

• Expectations placed on extrusion that can only be achieved through machining

• Design choices made without considering surface finishing or assembly

• Tolerances or profile lengths specified without reference to applicable standards

• Cost, lead-time, or repeatability issues identified too late to correct efficiently

These situations are common, avoidable, and often expensive to resolve once production is underway.

This guide has been created to help engineers, designers, and procurement teams avoid these pitfalls. Its purpose is to explain how bespoke aluminium profiles are manufactured in practice, what constraints exist at each production stage, and which design decisions have the greatest impact on cost, quality, and repeatability.

What this guide will help you do

This guide is intended as a practical design-for-manufacture reference.

It will help you to:

• Understand what aluminium extrusion can realistically achieve

• Select appropriate alloys based on functional, aesthetic, and cost requirements

• Identify when machining is required and how to design profiles to accommodate it

• Anticipate constraints related to surface finishing and anodising

• Align design intent with European EN standards

Throughout the guide, we highlight common design decisions, explain their manufacturing impact, and suggest practical alternatives where appropriate. The focus is not on what might be achievable under ideal or one-off conditions, but on what can be produced reliably, repeatedly, and economically in serial production.

Standards and scope

All dimensional guidance and tolerance references in this document are based on European Norms (EN standards), with primary reference to EN 755 for extruded aluminium products. This guide does not replace formal standards documentation, detailed engineering drawings, or project-specific technical validation. It is intended to support better technical decision-making and clearer communication with suppliers early in the project lifecycle.

2. Aluminium as a Material: Key Properties and Design Implications

Aluminium is widely used for extruded profiles because it combines low weight, good mechanical performance, and excellent manufacturability. In aluminium product design, these properties directly influence profile geometry, tolerances, surface finishing, and long-term behaviour in production and use.

Density and weight

Aluminium has a density of approximately 2.7 g/cm³, around one third that of steel. This allows significant weight reduction at both component and system level.

In practice, lower weight can:

• reduce loads on supporting structures

• improve handling and assembly

• lower energy consumption in use or transport

However, reducing weight by thinning walls or removing material must be balanced against stiffness, extrusion stability, and tolerance control.

Strength and stiffness

Aluminium alloys are available in a wide range of strengths depending on alloy and temper. However, aluminium has a lower elastic modulus than steel, meaning it deflects more under the same load.

For extruded profile design, this has a clear implication: stiffness is usually driven more by geometry than by alloy strength.

Increasing section depth, redistributing material, or modifying profile shape is often more effective than selecting a higher-strength alloy. Choosing a stronger alloy without addressing geometry rarely solves stiffness or deflection issues and can make extrusion and finishing more difficult.

Thermal behaviour

Aluminium has a relatively high coefficient of thermal expansion (23 µm per meter per degree of difference). Temperature changes can therefore lead to measurable dimensional variation, particularly in:

• long profiles

• assemblies with constrained interfaces

• applications exposed to temperature cycling

This behaviour should be considered when defining:

• functional clearances

• assembly fits

• tolerances over length

Ignoring thermal expansion at the design stage often leads to alignment issues or functional problems that cannot be corrected through tighter tolerances alone.

Corrosion resistance

Aluminium naturally forms a thin, dense oxide layer when exposed to air. This layer provides effective corrosion protection, and the oxide layer regenerates naturally when exposed to air.

In most neutral or mildly corrosive environments, aluminium performs well without additional protection. In more aggressive environments—such as strongly acidic or alkaline conditions—corrosion risk increases and must be addressed through:

• alloy selection

• surface treatment

• appropriate design measures

Surface finishing choices should therefore be considered early, as they can influence geometry, tolerances, and cost.

Machinability and formability

Aluminium is generally easy to machine and form. Cutting forces are low, tool wear is limited, and a wide range of machining operations can be carried out efficiently.

This allows functional features to be added where extrusion alone is not sufficient. However, machining should be used to add function, not to compensate for avoidable extrusion design issues. Features that can be integrated into the extruded shape will usually be more cost-effective and repeatable in serial production.

Thermal and electrical conductivity

Aluminium offers high thermal and electrical conductivity relative to its weight. This makes it well suited to applications involving:

• heat dissipation

• thermal management

• electrical performance

Profile geometry plays a major role here. Surface area, wall thickness, and airflow often have a greater impact on performance than material choice alone.

Durability and sustainability

Aluminium maintains its properties over long service lives and can be recycled indefinitely without loss of performance. Recycling requires significantly less energy than primary production.

For long-life or high-volume products, this supports both durability and lifecycle efficiency, provided profiles are designed for stable, repeatable production.

Key takeaways

• Aluminium enables lightweight and efficient profile designs

• Stiffness is driven primarily by geometry, not strength alone

• Thermal expansion must be considered, especially in long or precise components

• Natural corrosion resistance supports long service life, but environment and finishing matter

• Aluminium machines easily, but machining should add function, not correct poor design

• Profile geometry strongly influences thermal and electrical performance

3. 6xxx-Series Aluminium Alloys

Pure aluminium is relatively soft. To achieve useful mechanical performance, it is alloyed with controlled additions of other elements. The type and concentration of these elements directly influence strength, extrudability, machinability, surface finish, and cost.

The majority of bespoke aluminium profiles—including those produced at ALUCAD—are manufactured using 6xxx-series aluminium alloys. When working to European EN standards, these alloys offer the most reliable balance between mechanical performance, extrusion behaviour, machining capability, and surface finishing.

6082 is not part of ALUCAD’s standard alloy range but can be supplied for suitable projects and volumes, subject to technical validation.

Alloy choice and downstream processes

Alloy selection affects more than mechanical performance. It also influences:

• extrusion speed and process stability

• die wear and tooling cost

• machining behaviour

• anodising appearance and consistency

• distortion risk during production

Selecting an alloy without considering the full production chain often leads to compromises later in the project that are difficult or costly to resolve.

The most frequent issues encountered during alloy selection include:

• choosing high-strength alloys where geometry could achieve the same result

• expecting cosmetic anodising from structural alloys

• over-specifying strength “for safety” without functional justification

If appearance is critical, start with a cosmetic alloy and improve stiffness through geometry. If strength is critical, accept the trade-offs in surface quality, distortion risk, and cost.

Key takeaways

• Most bespoke profiles are produced using 6xxx-series aluminium alloys

• Standard 6xxx alloys include 6060, 6063, 6005, and 6061

• Cosmetic appearance and high strength rarely align in the same alloy

• Geometry optimisation is often more effective than increasing alloy strength

• Early alloy selection reduces cost, risk, and redesign

4. Principles of Aluminium Extrusion

Aluminium extrusion is a forming process. Understanding how it works in practice is essential when designing profiles that are manufacturable, repeatable, and economically viable. Many production issues arise when extrusion is expected to deliver machined-level precision, despite the fact that dimensional variation is inherent to the process.

This section explains the extrusion principles that most directly influence profile quality, tolerances, cost, and lead time.

What extrusion involves

Aluminium extrusion is a hot forming process. A heated aluminium billet is forced through a steel die under high pressure, producing a continuous profile with a fixed cross-section.

After extrusion, the profile is:

• Cooled and quenched (aging)

• Stretched to ensure straightness and reduce internal stresses (tensioning)

• Cut to length (press cutting)

Because aluminium flows under heat and pressure, extrusion behaviour is influenced by:

• Profile geometry

• Alloy selection

• Die design

• Press size and applied pressure

• Extrusion speed and cooling conditions

For this reason, extrusion standards such as EN 755 define achievable tolerance ranges, not absolute precision.

Press size, pressure, and profile diameter

In extrusion, a larger press does not automatically produce a better result. The applied pressure must be compatible with the profile’s circumscribed diameter, geometry, and wall distribution.

Applying excessive pressure to small or thin profiles can lead to:

• Flow imbalance

• Bending or distortion

• Surface defects

• Increased scrap risk

A press designed for wide or thick profiles cannot simply apply its full force to a small, delicate geometry without consequences. In such cases, the profile design—or its circumscribed diameter—must be adapted to suit the available press. Press capability and profile geometry must be matched, not forced.

Solid vs hollow profiles

Solid profiles

Solid profiles contain no enclosed voids. In practice, fully solid sections are rarely optimal for serial production. They increase material usage, weight, extrusion force, and handling effort without necessarily improving functional performance.

Solid sections are typically justified only where:

• Internal cavities would compromise function

• Load paths or interfaces cannot accommodate hollows

Hollow profiles

Hollow profiles contain one or more enclosed voids and are produced using bridge or porthole dies.

Where functionally possible, hollow sections are generally preferred because they:

• Reduce profile weight

• Improve handling and process stability

• Often reduce extrusion force

• Maintain functional performance when properly designed

• Do not typically increase tooling cost

The longitudinal weld seams formed during hollow extrusion are metallurgically sound and fully covered by EN standards. Where relevant, their position is considered during design to avoid functional or cosmetic impact.

Solid profiles should not be used by default. Hollowing a profile is often the most effective way to improve both manufacturability and cost efficiency.

Wall thickness balance

Very thin walls are technically possible, but they increase risk and reduce process stability.

Good practice includes:

• Avoiding extreme minimum wall thicknesses

• Keeping wall thickness as uniform as possible

• Avoiding abrupt transitions between thin and thick sections

Large thickness variations cause uneven metal flow, which leads to distortion, tolerance variation, and reduced surface quality.

Symmetry and flow balance

Symmetrical profiles extrude more predictably because aluminium flow is balanced across the die.

Asymmetrical profiles increase:

• Twist and bow

• Sensitivity to cooling conditions

• Difficulty maintaining tight tolerances

In practice, material is sometimes added, not removed, to balance metal flow across different areas of the die. For tolerance control, flow balance is often more important than minimising material.

Cantilever length and die-side adjustments

Cantilever length refers to the unsupported length of profile elements extending from the die.

Excessive cantilever length can cause:

• deflection during extrusion

• Flow instability

• Poor dimensional repeatability

Adjusting cantilever length is one of the most common die-side changes during extrusion development. These adjustments are made to improve flow control and stability, not to increase strength. When an extruder requests cantilever modifications, it is almost always to improve tolerance consistency and production robustness.

Single-exit vs multi-exit dies

Multi-exit dies can increase output but significantly complicate flow control.

Multiple exits increase the risk of:

• Uneven metal flow between cavities

• Dimensional variation between profiles

• Reduced tolerance consistency

Where tolerance control, repeatability, or cosmetic quality are critical, single-exit dies are generally preferred. Increased output is meaningless if production is unstable or inconsistent. In practice, more exits often mean more problems.

Tolerances under EN standards (EN 755)

A common misunderstanding is treating extrusion as a precision process.

EN 755 defines dimensional tolerances, limits for straightness, twist, and bow, and general flatness expectations. These limits reflect what is realistically achievable in extrusion.

Specifying unnecessarily tight tolerances on as-extruded features:

• Rarely improves functional performance

• Significantly increases extrusion difficulty

• Increases inspection time, scrap risk, and cost

In some cases, over-specified tolerances can multiply profile cost without adding value. Where positional accuracy, flatness, or tight dimensional control are functionally critical, those features should be defined for machining.

Surface quality and flat faces

Long, uninterrupted flat faces tend to show extrusion lines and flow marks, which become more visible after anodising.

To manage cosmetic expectations:

• Avoid large flat surfaces where possible

• Introduce ribs, radii, or surface features

• Recognise that perfectly flat cosmetic surfaces usually require post-processing

Polishing prior to anodising can reduce visible variation, but minor differences will still remain.

ALUCAD production note

At ALUCAD, typical maximum extruded profile lengths are approximately 5,850 mm, primarily to ensure compatibility with container transport and downstream handling.

Key takeaways

• Aluminium extrusion is a forming process, not precision machining

• Press size and applied pressure must match profile geometry

• Balanced wall thickness and symmetry improve flow and tolerance control

• Cantilever length strongly influences stability and repeatability

• Single-exit dies offer better consistency where tolerances matter

• EN 755 defines realistic extrusion tolerances

• Unnecessary tight tolerances significantly increase cost

• Removing material often improves both quality and economics

• Cosmetic surfaces must be designed with extrusion behaviour in mind

5. Principles of Machining Extruded Profiles

For most bespoke aluminium profiles, machining is how function is defined. Extrusion establishes the basic cross-section, but machining creates the features that control assembly, alignment, interfaces, and dimensional accuracy.

For this reason, machining must be considered during the earliest design stages. When extrusion design and machining strategy are aligned from the outset, unnecessary operations are avoided, dimensional control improves, and costly corrections later in the production process are reduced.

What machining delivers

Machining is not used to “improve” an extruded profile. It is used to define where accuracy actually matters.

Extrusion creates a profile within EN-defined tolerances, but it does not establish precise functional relationships between features. Machining does. Machined features define how parts are located during assembly, where loads are transferred, how interfaces mate or seal, and which surfaces are used for measurement and inspection.

Using machining to define functional references

Without clear machined reference surfaces, small dimensional variations from extrusion accumulate across assemblies. Individual parts may remain within tolerance, but assembly becomes inconsistent, alignment suffers, and downstream adjustment is often required.

This typically occurs when functional interfaces are referenced directly from as-extruded surfaces, or when tight tolerances are applied broadly without a defined functional hierarchy.

An effective machining strategy establishes a clear datum system. A limited number of machined reference surfaces are defined, and all critical features are positioned relative to those references. Accuracy is concentrated where it matters, preventing tolerance stack-up.

As a result:

• Functional relationships between features are controlled

• Part-to-part consistency is maintained

• Inspection reflects functional requirements rather than arbitrary dimensions

This approach does not reduce performance requirements. It is how tight functional requirements are achieved reliably and repeatedly in serial production.

Machining setup strategy: fewer setups, better results

Every time a profile is re-clamped, variability increases.

Effective machining design aims to:

• Machine all critical features in as few setups as possible

• Keep reference faces consistent between operations

• Avoid machining on multiple unrelated sides unless functionally required

Profiles that require repeated re-orientation:

• Take longer to machine

• Are harder to control dimensionally

• Cost more and yield less consistently

If a feature can be repositioned onto a common machining face without affecting function, it usually should be.

Profile stiffness and machining behaviour

Extruded profiles are often long and relatively flexible. During machining, cutting forces can cause:

• Local deflection

• Dimensional drift

• Surface quality issues

To manage this, machining strategy must account for:

• Profile stiffness

• Clamping and support points

• Cutting forces and tool paths

In many cases, small changes to extrusion geometry—such as rib placement, wall distribution, or internal hollows—significantly improve machining stability and reduce cycle time.

Feeding machining constraints back into extrusion design

Extrusion design can often be adjusted to improve machining behaviour.

Typical improvements include:

• Adjusting wall thickness to reduce movement

• Improving symmetry to stabilise clamping

• Reducing cantilevered features

• Introducing hollows to reduce weight without affecting function

In practice, modest changes to the extruded profile often reduce machining time more effectively than adding machining operations. This improves both production speed and total cost.

Custom tooling and fixtures

Standard cutting tools are designed for generic parts. Bespoke aluminium profiles rarely behave like generic parts.

Purpose-built tooling and fixtures allow:

• Tighter tolerances over long production runs

• Multiple features to be machined in a single operation

• Reduced cycle time without increased risk

• Improved surface quality on complex geometries

• Earlier detection of wear or dimensional drift

Because tooling can be adapted quickly, iteration cycles are shorter and break-even volumes are lower than is often assumed. Custom tooling is therefore used where it improves total production efficiency—not only at very high volumes.

ALUCAD production note

Custom machining tools and fixtures are designed and produced in-house. This reduces the time and cost typically associated with external tooling development, resulting in more efficient and cost-effective machining and production of extruded aluminium products.

Machining sequence and dimensional stability

Machining releases internal stresses from extrusion and cooling. This can cause slight movement, particularly in:

• Long profiles

• Asymmetrical sections

• Profiles with significant material removal

These effects are controlled through:

• Defined machining sequences

• Balanced material removal

• Controlled clamping and support

Critical features are always machined after stabilising operations, not before.

Common machining-related design mistakes

The most frequent issues include:

• Applying tight tolerances to non-functional features

• Distributing tight tolerances across multiple unrelated faces

• Designing profiles that require machining on every side

• Treating machining as a corrective step rather than a design tool

Apply tight tolerances only where they affect function, and concentrate them around a clear datum strategy.

Key takeaways

• Machining defines how a profile functions and assembles

• Controlled datum surfaces matter more than global tight tolerances

• Fewer setups improve consistency and reduce cost

• Small extrusion changes often reduce machining effort significantly

• Custom tooling improves precision, speed, and repeatability

6. Anodisation & Other Surface Treatments

Surface treatment should be determined during profile design, alloy selection, extrusion quality, and machining strategy. Profile geometry, alloy choice, length, machining sequence, and tolerance definition all directly influence which surface finishes are achievable, how consistent they will be in production, and at what cost.

Anodising: what it does (and does not do)

Anodising is an electrochemical process that converts the surface of aluminium into a controlled oxide layer. This layer:

• Improves corrosion resistance

• Increases surface hardness

• Allows colouring, depending on alloy and process

• Reduces electrical conductivity at the surface

• Slightly reduces thermal conductivity at the surface compared to bare aluminium

Anodising is not a coating. The oxide layer grows from the aluminium itself. As a result:

• Surface condition before anodising is critical

• Alloy composition directly affects appearance

• Contact points during processing are unavoidable

Anodising does not hide defects. Die lines, flow marks, scratches, and machining marks remain visible and are often accentuated. If a surface must appear uniform after anodising, it must already be uniform beforehand.

Alloy choice and anodising appearance

Not all aluminium alloys anodise in the same way.

Alloys optimised for surface quality, such as 6060 and 6063, typically produce:

• More uniform colour

• Cleaner, more consistent appearance

Higher-strength alloys, such as 6061 and 6082, often show:

• Colour variation

• Streaking or patchiness

• Greater sensitivity to process variation

Pursuing cosmetic anodised finishes on structural alloys frequently leads to additional processing, rework, or rejection without improving functional performance. If appearance is critical, alloy selection must prioritise anodising behaviour early—even if this requires accepting lower mechanical strength and compensating through geometry.

Anodising before or after machining

Pre-machining anodising

The profile is anodised first, then machined.

Advantages:

• Uniform anodised finish on visible extruded faces

• Lower anodising cost

• Suitable when machined areas are hidden or non-cosmetic

Limitations:

• Machined surfaces remain un-anodised

• Visible colour contrast between anodised and raw aluminium

Post-machining anodising

The profile is fully machined, then anodised.

Advantages:

• Anodised finish on all faces

• Best cosmetic consistency on finished parts

Limitations:

• Higher cost

• Additional handling and process steps

• Tighter control required on dimensions and surface condition

Post-machining anodising should be reserved for parts where full cosmetic consistency is functionally or commercially justified.

Contact points, racking, and handling during anodising

During anodising, profiles must be electrically connected and mechanically supported. This requires contact points, which will leave visible marks. These marks are unavoidable.

When anodising is carried out before machining, additional material can be allowed so that contact areas are later removed. For long profiles, additional support points may be required.

When anodising is carried out after machining, contact marks remain on the finished part and must be planned for in the design.

Other surface treatments

Polishing

• Improves surface appearance before anodising or coating

• Adds processing time and cost

• Best reserved for visible, high-value surfaces

Lacquering / powder coating

• Offers greater colour flexibility than anodising

• More forgiving of minor surface variation

• Adds coating thickness that must be considered in tolerance definition

Sanding, sandblasting / surface preparation

• Used to reduce extrusion lines or machining marks

• Improves surface uniformity and appearance

• Adds processing time and cost

• Requires controlled, consistent application to avoid uneven results

Key takeaways

• Surface finishing outcomes are determined early in the design

• Anodising improves protection but highlights surface defects

• Alloy choice strongly influences anodising appearance

• Pre-machining anodising leaves cut surfaces raw; post-machining anodising leaves contact marks

• Contact marks for post-machining anodising are unavoidable and must be designed for

• Early finish selection avoids rework and unnecessary cost

7. Assembly, Packaging & Delivery

Assembly, packaging, and delivery are often treated as downstream activities. In practice, they are a direct continuation of the design process. Profiles that are designed with assembly and transport in mind are easier to handle, less prone to damage, and more economical to deliver.

For this reason, these stages should be considered early, alongside extrusion, machining, and finishing—not as add-ons at the end of the project.

Assembly considerations

Depending on project requirements, profiles may be supplied as:

• Individual machined components

• Sub-assemblies

• Fully assembled units

• Assemblies integrating aluminium and non-aluminium parts

Assembly operations typically include:

• Mechanical fastening

• Insertion of hardware

• Alignment and functional checks

• Preparation for direct installation

For serial or repeat assemblies, integrating assembly operations upstream reduces handling, assembly errors, and internal labour at the customer’s facility, while enabling earlier detection of defects and faster corrective action. In many cases, this lowers total landed cost by simplifying logistics and reducing rework.

Designing profiles for efficient assembly

Profiles that assemble reliably tend to share the same design principles:

• Clearly defined datum surfaces

• Accessible and logically positioned fixing points

• Consistent interfaces and hole patterns

• Tight tolerances applied only where they affect function

Assembly issues frequently arise from over-constrained designs, where multiple tight tolerances interact unnecessarily. If two parts must fit together, one feature should control the fit. Other related dimensions should be allowed to float within realistic limits.

Designing for assembly is primarily about controlling interfaces, not tightening every dimensional tolerance.

Packaging considerations

Packaging should be designed around the part and the transport conditions. It is not a generic solution.

Packaging requirements depend on:

• Profile length and stiffness

• Surface finish (raw, anodised, polished, coated)

• Assembly state (individual parts or assemblies)

• Transport method and distance

Effective packaging typically combines:

• Protective films where appropriate

• Spacers or separators to prevent contact

• Crates or pallets designed for the specific geometry

Finished surfaces—particularly anodised, polished, or coated parts—are sensitive to:

• Abrasion

• Contact marks

• Vibration during transport

Packaging design must therefore consider:

• Contact points between parts

• Stackability

• Movement during handling and transport

Addressing these points early reduces transit damage, disputes, and rework at far lower cost than replacing damaged components.

Key takeaways

• Assembly, packaging, and delivery are extensions of the design process

• Upstream assembly can reduce total cost and operational complexity

• Clear datum strategy improves assembly yield and consistency

• Packaging must be matched to surface finish and transport conditions

8. Design Checklist Before Sending an RFQ

Before requesting a quotation for a bespoke extruded aluminium product, reviewing the points below will significantly improve quotation accuracy, technical feasibility, lead time, and final part quality.

This checklist is intended for both engineers and buyers. It reflects the most common causes of redesign, cost increase, and delay observed when aluminium profiles are not designed with manufacturing reality in mind.

1. Material and alloy selection

• Is the selected alloy appropriate for both mechanical requirements and surface finish expectations?

• Are cosmetic requirements compatible with the chosen alloy?

• Has stiffness been optimised through geometry before selecting a higher-strength alloy?

• Are machinability and distortion risk acceptable for the selected alloy?

• Will surface treatment (e.g. anodising) affect thermal or electrical performance?

2. Profile geometry and extrusion design

• Are wall thicknesses balanced and realistic for stable extrusion?

• Is the profile as symmetrical as function allows to promote balanced metal flow?

• Have unnecessary solid sections been hollowed where function allows?

• Are cantilever lengths controlled to reduce flow instability and distortion?

• Are sharp internal corners avoided where possible?

• Is a single-exit die preferred where tolerance control or cosmetic quality is critical?

• Is the profile compatible with realistic press size, pressure, and circumscribed diameter?

3. Tolerances and standards

• Are tight tolerances applied only to features that control function or assembly?

• Are as-extruded and machined features clearly distinguished on drawings?

• Is the datum strategy clear for machining and inspection?

• Are tolerance requirements realistic for serial production?

4. Length, handling, and logistics

• Is the profile length compatible with extrusion, finishing, handling, and transport constraints?

• If longer lengths are required, has the impact on straightness, finishing quality, and packaging been discussed early?

• Could the design be modularised and assembled after cutting to length?

• Has handling during machining, finishing, packaging, and delivery been considered?

5. Machining considerations

• Are all functional interfaces and reference features defined to be machined?

• Is the machining orientation clear and logically aligned with the datum strategy?

• Can critical features be machined in as few setups as possible?

• Has profile stiffness during machining been considered?

• Have custom tools or fixtures been considered for recurring or precision features?

6. Surface treatment and finishing

• Is anodising, coating, or other surface treatment compatible with the selected alloy?

• Has pre-machining versus post-machining anodisation been clearly defined?

• Are acceptable anodising contact areas identified and located on non-cosmetic faces?

• Are surface quality expectations realistic for the selected process?

• Is sanding or polishing specified only where it adds functional or commercial value?

7. Assembly, packaging, and delivery

• Would assembly at source reduce total cost, handling, or risk?

• Are datum surfaces and interfaces suitable for reliable assembly?

• Are packaging and surface protection requirements clearly defined?

• Is the part protected against contact, abrasion, and vibration during transport?

• Is the delivery format compatible with handling and installation at the destination?

9. Designing Bespoke Extruded Aluminium Products That Work in Practice

Bespoke extruded aluminium products offer significant design freedom, but that freedom delivers value only when it is aligned with manufacturing reality.

This guide is not intended to restrict creativity. Its purpose is to enable better decisions from the outset, before certain choices lead to avoidable problems. Most production issues stem from assumptions made during the design phase, without full visibility of downstream constraints.

Applying the principles outlined in this guide from the outset helps achieve:

• More accurate and reliable quotations

• Shorter and more predictable lead times

• Higher first-time-right quality

• Fewer late-stage design changes and compromises

Successful aluminium products are not optimised at a single stage. They result from considering extrusion, machining, surface finishing, assembly, and logistics as parts of one coherent system, while meeting the required functional and performance criteria.

Early technical dialogue leads to better outcomes. When design intent and manufacturing constraints are aligned from the beginning, aluminium profiles perform as intended—both in production and in use.

Next step

For projects at RFQ stage, designs can be reviewed from a manufacturability perspective to identify potential risks and improvement opportunities before commitments are made.

To discuss a project, email us at contact@alucad.com.

Designing Bespoke Extruded Aluminium Products for Efficient Manufacture

1. About ALUCAD & Purpose of This Guide

Why this guide exists

What this guide will help you do

Standards and scope

2. Aluminium as a Material: Key Properties and Design Implications

Density and weight

Strength and stiffness

Thermal behaviour

Corrosion resistance

Machinability and formability

Thermal and electrical conductivity

Durability and sustainability

Key takeaways

3. 6xxx-Series Aluminium Alloys

Why 6xxx-series alloys are preferred

6xxx-series alloys’ properties

6060

Characteristics

Limitations

Cost perspective

6063

Characteristics

Limitations

Cost perspective

6005

Characteristics

Limitations

Cost perspective

6061

Characteristics

Limitations

Cost perspective

6082

Characteristics

Limitations

Cost perspective

ALUCAD production note

Alloy choice and downstream processes

Key takeaways

4. Principles of Aluminium Extrusion

What extrusion involves

Press size, pressure, and profile diameter

Solid vs hollow profiles

Solid profiles

Hollow profiles

Wall thickness balance

Symmetry and flow balance

Cantilever length and die-side adjustments

Single-exit vs multi-exit dies

Tolerances under EN standards (EN 755)

Surface quality and flat faces

ALUCAD production note

Key takeaways

5. Principles of Machining Extruded Profiles

What machining delivers

Using machining to define functional references

Machining setup strategy: fewer setups, better results

Profile stiffness and machining behaviour

Feeding machining constraints back into extrusion design

Custom tooling and fixtures

ALUCAD production note

Machining sequence and dimensional stability

Common machining-related design mistakes

Key takeaways

6. Anodisation & Other Surface Treatments

Anodising: what it does (and does not do)

Alloy choice and anodising appearance

Anodising before or after machining

Pre-machining anodising

Post-machining anodising

Contact points, racking, and handling during anodising

Other surface treatments

Polishing

Lacquering / powder coating

Sanding, sandblasting / surface preparation

Key takeaways

7. Assembly, Packaging & Delivery

Assembly considerations

Designing profiles for efficient assembly

Designing Bespoke Extruded Aluminium Products
for Efficient Manufacture