What is Aluminum Extrusion? Definition and Application

October 11, 2021

The manufacturing industry has always been a very competitive one. The competition is intensified with globalization. Manufacturers are always looking for ways to cut costs and improve production capacity by making more products in less time with the least energy consumption possible. And they find that tapping into modern technology is the driving force behind the industry's potentials.

Aluminum extrusion is a modern technology that enables manufacturers to reduce production costs and speed up output. This manufacturing method has changed the traditional production procedure from metal sheets, bars, and tubes. Here's what you need to know about aluminum extrusion.

What is Aluminum Extrusion?

Aluminum extrusion is a cold-forming process of producing metal shapes from aluminum and aluminum alloys by squeezing the material between two or more shaped dies. The first die determines the cross-section of the product and acts as a "mother" die while the other die is called "daughter."

These dies are attached to a rotating screw that forces the material to flow through the dies. The material then passes through shaped cavities in the dies, which produce the extrusion profile.

Aluminum extrusions result in products with very complex geometry and smooth surfaces. In addition, aluminum extrusion is usually combined with other metal forming methods such as drawing, rolling, and spinning to further enhance the product's appearance and achieve higher tolerances.

The combination of these modern technologies has made today's aluminum extrusions lightweight but strong enough for a wide range of applications.

Application of Aluminum Extrusion

Aluminum extrusion has a wide range of applications in several industries such as:

Aerospace and defense

These extrusions find their way to parts of aircraft and military vehicles such as helicopter blades, wing components, and fuselage panels. Aluminum's low density and structural integrity have made it a go-to material for these applications.


They have helped automotive designers achieve weight reduction in cars to improve fuel economy without sacrificing product performance or safety. Aluminum extrusions are used as door beams, chassis components, floor panels, hydraulic lines, and brake calipers for cars.

Building and construction

These aluminum products are used for roofing, windows, exterior cladding panels, industrial door structures, industrial casings, and other building materials. Aluminum is an ideal metal for these applications because it does not corrode easily under harsh weather conditions. It also resists damage from insects, mold, and fungi.

Energy and power

The oil and gas industry finds aluminum extrusions a reliable material for pipelines, valves, and other components. In addition, aluminum's corrosion resistance has made it an ideal metal for these applications. It is also used in power tools such as the generator housing of the wind turbine.

Household appliances

Aluminum extrusions are used in small appliances such as washing machines, microwave ovens, and vacuum cleaners. They are also found in larger appliances such as refrigerators, freezers, and air conditioners. In addition, aluminum extrusions can be used to make parts such as door panels, pullout racks, appliance cabinets, and base rails.

Benefits of Aluminum Extrusion

There are several benefits of aluminum extrusion, which is why it has become a popular manufacturing method for various industries. These include:


Aluminum extrusions are easily formed into complex geometries. This makes it possible to create products that have intricate details and smooth surfaces without machining after extrusion. The process also enables manufacturers to achieve a high level of dimensional accuracy.

Corrosion resistance

Aluminum's corrosion resistance makes it a good choice for applications that are exposed to harsh conditions or atmospheric elements such as air, water and heat. Products made from aluminum also do not contain harmful elements such as mercury, lead and chrome. This makes them safe for food processing and contact with beverages.


Aluminum is a lightweight metal that makes it a suitable material for load-bearing designs. It is also easy to machine or cut, which enables manufacturers to reduce the weight of their products without sacrificing strength. This is beneficial for transportation applications such as cars, trucks, and planes.


It is a reusable and recyclable metal. This means you can save that time, energy, and money during the production process because aluminum extrusions do not require additional machining after extrusion. Aluminum also has a high rate of recycling, which is why it is considered an eco-friendly material.

Final Thoughts

Aluminum extrusion has several benefits that make it a popular manufacturing method for various industries. It has helped designers create innovative products and has contributed to the efficiency of many operations.

The low weight of aluminum also makes it a suitable material for transportation applications. Therefore, as long as there is a demand for aluminum, the metal will play an essential role.

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