Manufacturing process

Extrusion

Extrusion pushes heated material through a shaped die to create long profiles with a constant cross-section — most commonly aluminium profiles that are then cut, machined and finished.

Process overview

Extrusion forms material through a shaped die to create continuous profiles with a defined cross-section. It is used for aluminum and other metals as well as selected plastics, supporting both standard and custom profile geometries. Manufacturing requirements can include material grade, profile dimensions, tolerances, tooling, cut length, surface treatment and secondary machining.

For aluminium, a preheated billet is pressed through a steel die; the emerging profile is cooled, stretched, cut to length and artificially aged to its final temper. Solid, semi-hollow and hollow sections are possible, with hollow profiles made through porthole or bridge dies. Die costs are modest compared with casting or stamping tools, which makes custom profiles accessible even at moderate volumes — often planned in kilograms or tonnes per year rather than pieces.

Profile design affects extrudability and cost. Balanced wall thicknesses, generous radii and a compact circumscribing circle generally extrude more easily and hold tolerances better. Standard dimensional tolerances for aluminium profiles are commonly taken from EN 755-9, or EN 12020 for precision profiles in suitable alloys.

Plastic profiles and pipes are produced by plastic extrusion, covered under plastics processing. Many aluminium extruders add value through cutting, CNC machining, anodising, powder coating and assembly.

Typical capabilities & what manufacturers can produce

What manufacturers can produce

  • Custom structural and architectural profiles
  • Heat sinks and electronics housings
  • Frames and rails for machines, automation and solar mounting
  • Tubes and hollow sections
  • Cut-to-length, drilled and CNC-machined profile parts
  • Anodised or powder-coated finished profiles

Suitable materials

Materials commonly used with this process — an editorial reference, not a statement about facilities in the Metraxio network. Suitability always depends on the part and its application.

  • Aluminum

    The dominant extrusion material; 6xxx alloys such as 6060 and 6063 are most common.

  • Aluminum 6082

    Higher-strength alloy for structural profiles.

  • Aluminum 6061

    Structural profiles, often supplied in the T6 temper.

  • Copper

    Busbars and conductor profiles.

  • Brass

    Extruded rods and profiles for machining.

  • PVC

    Plastic window profiles and pipes, produced by plastic extrusion.

Relevant industries

Industries whose Metraxio industry guides list Extrusion as a common process, with the typical use in each.

What buyers should specify

The details that make Extrusion quotes comparable and let facilities be assessed on the right criteria.

Cross-section drawing
Profile drawing with critical dimensions and wall thicknesses; a DXF of the section helps.
Alloy and temper
For example 6060-T66 or 6063-T6 for architectural and decorative use, 6082-T6 for structural parts.
Length and quantity
Cut lengths and their tolerance, plus annual tonnage or pieces.
Profile tolerances
Standard (EN 755-9) or precision (EN 12020) tolerances, or specific critical dimensions.
Surface finish
Mill finish, anodising (thickness class and colour) or powder coating (RAL), and which faces are visible.
Secondary operations
Machining, punching, bending or assembly after extrusion.
Die
New die required or existing die, and die ownership.

On Metraxio these details become a structured manufacturing requirement. Processes, capabilities, materials, certifications and part size are checked against facility profiles; tolerances, finishes and inspection details travel with your drawings and are reviewed during quoting rather than used as automatic filters.

Frequently asked questions

How much does an extrusion die cost?

Aluminium extrusion dies are generally inexpensive compared with casting or stamping tools. Cost depends on profile size and complexity, and hollow profiles cost more than solid ones.

Is there a minimum order quantity?

Extruders often set minimums by weight per run rather than by pieces. For small quantities, a standard profile machined to shape may be cheaper than a custom die.

Which aluminium alloy should I use?

6060 and 6063 extrude easily and anodise well; 6082 and 6061 offer higher strength for structural parts. Strength, finish and profile shape decide.

Extrusion by country

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