Aluminium extrusion pushes a hot aluminium billet through a steel die to make long lengths with a constant cross-section, called profiles or sections. Almost any 2D shape is possible, including hollow ones. Extrusions are cut to length and often machined, anodised or powder coated. They are used for window frames, heat sinks, rails, frames, enclosures and machine parts.
Quick facts
- Alloys
- 6063 (most common), 6061, 6082, 6351
- Size
- Fits inside a circle of about 20–300 mm (0.787–11.81 inch) on common presses
- Wall thickness
- About 1 mm (0.0394 inch) upward
- Die
- Steel die, made for each profile
- Lengths
- Usually up to about 6 m, then cut
- Usually priced
- Die cost once, then per kg
How it is done
- A die is made to the profile drawing
- Billets are heated to about 450–500 °C
- The press pushes the billet through the die
- Profiles are stretched straight and cut to length
- They are aged (T5 or T6) for strength, then finished
Finishes and operations
- Anodising (clear or coloured)
- Powder coating
- Cutting to length, drilling, punching and CNC machining
- Brushing or polishing
What to send
- Profile drawing with all sizes and tolerances
- Alloy and temper (for example 6063-T6)
- Length per piece and quantity in kg or metres
- Finish needed
- Machining after extrusion, if any
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Questions
- What is the minimum order for a custom profile?
- Extruders usually ask for a minimum quantity per run, often a few hundred kg, because each run needs the press set up with the die.
- Who owns the die?
- Usually the buyer pays for the die; agree in writing that it is yours and stays reserved for your orders.
- Can hollow profiles be extruded?
- Yes, with porthole (bridge) dies; they cost more than dies for open shapes.
The figures on this page are typical values for guidance, written by Diemeco from standard engineering practice. They are not a specification: confirm grades and properties with the relevant standard or the supplier's mill test certificate, and tolerances with your workshop. Last checked 29 October 2026.