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Home > Custom Aluminum Extrusion

Custom Aluminum Extrusions

Discover how custom aluminum extrusions can be designed to meet the unique demands of industries from automotive to electronics, offering precision, durability, and flexibility

Low MOQ

Start your project with a small minimum order, reducing your upfront costs and risk.

Fast Lead Time

1-2 weeks for tooling time. Quickly bring your designs to life and shorten your product launch timeline.

Engineering Support

Translating complex design requirements into workable molds and extrusions.

CNC Fabrication

Cutting, CNC turning, precision CNC milling, bending, welding, and assembly.

Custom Aluminum Extrusion: Tailored Solutions for Every Industry

At Fusion Aluminum, we specialize in producing high-quality custom aluminum profiles tailored to meet the specific needs of our clients across various industries. Our custom profiles are designed with precision and manufactured using advanced technology, ensuring excellent performance and durability.

Aluminum heat sink

For efficient thermal management, commonly used in electronics and lighting to dissipate heat and ensure optimal performance.

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Aluminum enclosure

Providing durable, lightweight protection for electronics, commonly used in telecommunications and consumer electronics.

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Aluminum handle

Offering both durability and a sleek, modern appearance for appliances like refrigerators, ovens, cabinets, and doors.

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Aluminum track

With our precision CNC machining, ensuring smooth operation and long-lasting performance for automotive sunroofs, automation system.

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Aluminum beam

Providing durable, lightweight protection for electronics, commonly used in telecommunications and consumer electronics.

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Need a custom aluminum extrusion?

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How much does an aluminum extrusion tool cost?

The cost of a custom aluminum extrusion mold can be different depending on the following factors:

Size of the aluminum section: The larger the aluminum extrusion shapes, the more expensive the mold. For example, a simple U-channel aluminum extrusion with dimensions of 60mm x 30mm would need a mold size of around 148mm x 100mm. In this case, the tooling cost is between $300 to $400.

Product structure: If you are working with more complex products like hollow custom aluminum profiles, such as aluminum tubes or enclosures, you will need a split-flow mold. This type of mold requires two sets to complete and costs about $100 to $200 more than a flat mold used for simpler profiles like heat sinks or U-channels.

Weight of the aluminum product: The heavier the product, the stronger the mold needs to be. Heavier custom aluminum extrusions require molds that can handle more pressure, which increases both the thickness and outer diameter of the mold. As a result, the cost of the mold goes up.

Flat mold

Split flow mold

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What materials are used for aluminum extrusion?

When selecting aluminum alloys for extrusion, it is necessary to consider the properties required of the final product, including strength, corrosion resistance, surface quality, extrudability, heat treatment requirements, and cost.

6063 Aluminum
One of the most commonly used custom aluminum extrusion alloys, known for its excellent mechanical properties and weldability. It’s widely used in custom aluminum profiles for architectural structures, furniture, and decorative applications.

6061 aluminum
This alloy offers good mechanical properties and corrosion resistance, making it ideal for custom aluminum extrusions used in manufacturing refrigerator components, container floors, truck frames, and various vehicle track structures.

6082 aluminum
They are frequently used in applications where high strength and corrosion resistance are required, such as custom extruded aluminum profiles for vehicle structural components.

6005 aluminum
This alloy is commonly used to produce high-strength aluminum extrusion shapes, such as ladders, TV antennas, and masts.

7005 aluminum
A high-strength alloy often used in custom aluminum extrusion projects that require strength and corrosion resistance, such as bicycle frames.

7075 aluminum
Known for its high strength and hardness, this alloy is commonly used in aerospace and defense industries for custom extruded aluminum profiles, where lightweight and high strength are critical.

What is the maximum size of custom aluminum extrusion?

The maximum size of aluminum extrusion shapes is limited by several factors, including the capacity of the extrusion press and the design of the mold. Most standard extrusions have a diameter smaller than 8 inches (203.2mm), but some large extrusion presses can produce custom aluminum extrusions with diameters as large as 18 inches (457.2mm). This typically requires larger molds and higher extrusion pressure.

Round Aluminum extrusion: Max 400mm in diameter

Square aluminum extrusion: Max 340x340mm

Rectangle aluminum extrusion:
Max 400x200mm, 580x120mm, 750x50mm

Maximum extrusion size

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Steps to make custom aluminum extrusion with Fusion aluminum.

As a leading custom aluminum extrusion manufacturer, it is easy to work with Fusion Aluminum to make your custom aluminum extrusion profiles.

1. Consultation and quotation

Discuss with the client to understand your specific needs, including dimensions, shape, thickness, and application of the aluminum profile.

2. DFM report

DFM (Design for Manufacturability) report can help engineers consider the characteristics of the extrusion process during the product design stage. It ensures the quality of the custom aluminum extrusions, reduces cost, and improves production efficiency.

Larger extrusions require bigger molds and larger extrusion presses. The farther the metal is from the center of the extrusion die, the slower the metal flows.

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3. Mold design and development

After the design of the aluminum extrusion profile is confirmed, we will start design and make the mold.

4. Mold test and sample

A sample at the required length will be sent to you for approval. We can also adjust the mold if your requirements are slightly changed.

5. Extrusion process

After the sample is approved, will will start the extrusion process. The lead time for bulk orders is around 15-25 days depending on the order quantity.

6. Surface treatment

Fusion aluminum provides a variety of surface treatments for aluminum extrusion profiles, including brushing, polishing, anodizing, wood texture, powder coating, to enhance both the appearance and durability of our custom aluminum extrusions.

7. CNC fabrication (if need)

Our machining services include cutting, CNC milling, drilling, punching, stamping, welding, and bending. With advanced equipment, we can deliver the highest quality custom aluminum profiles, tailored to your exact specifications.

8. Packing and shipment

We provide different kinds of packing for custom aluminum extrusions, like wrapping, bundling, wooden palets, or crates. For finished products, we can also customize the carton boxes for you.

Why Choose Fusion Aluminum?

Low MOQ

Start your project with a small minimum order, reducing your upfront costs and risk.

1-2 weeks for mold development

Quickly bring your designs to life and shorten your product launch timeline.

2000+ standard molds

Save on mold costs by choosing from a wide selection of existing molds, speeding up production.

Fast response within 24 hours

Get the answers you need without delay, ensuring smooth communication and faster decision-making.

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