Custom Glass Railing Corner Shape Aluminum Profile Channel Extrusion

The shapes we see above are all relatively simple, but the extrusion process also allows for the creation of shapes that are much more complex.

What Kinds of Shapes Can be Extruded?

There are four main categories of extruded shapes:

Solid, with no enclosed voids or openings (i.e. a rod, beam, or angle).

Hollow, with one or more voids (i.e. square or rectangular tube).

Heat sink,Mainly used for LED lamps or equipment heat dissipation, the shape is radial or comb, etc


Non-standard irregular shapes, usually these aluminum profiles are designed for specific product uses and are structured by product designers.

Extrusion has innumerable applications across many different industries, including the architectural, automotive, electronics, aerospace, energy, and other industries.

The Aluminum Extrusion Process mainly in 3 Steps 

Step 1: The Extrusion Die is Prepared and Moved to the Extrusion Press

First, H13 steel is machined into a round die. Or, if one is already in stock, it is retrieved from a warehouse similar to this one. 

Prior to extrusion, the die must be warmed to between 450 and 500 degrees celsius to increase its durability and ensure uniform metal flow. 

After preheating the die, it can be placed into the extrusion press.

Step 2: The Extruded Material Emerges Through the Die


As the container is filled with alloy material, it is now being forced against the extrusion die. 

When aluminum is subjected to constant pressure, it has nowhere to go except via the aperture in the die. 

It emerges out the opening of the die with a completely formed profile.

Step 3: Extrusions are Moved to the Stretcher and Cut to Length


With the table-length extrusions now straight and fully work-hardened, they are transferred to the saw table.

Here, they are sawed to pre-specified lengths, generally between 8 and 21 feet long. At this point, the properties of the extrusions match the T4 temper.

After sawing, they can be moved to an aging oven to be aged to the T5 or T6 temper.

What Occurs Next? Heat Treatment, Surface Treatment, and Fabrication 

After extrusion, profiles can be treated with heat to improve their characteristics. 

Then, following heat treatment, they can get a variety of surface treatments to improve their aesthetics and corrosion resistance. 

They may also be subjected to fabrication techniques to attain their ultimate dimensions.

Heat Treatment: Improving Mechanical Properties

Aluminium Alloys in the 6000, and 7000 series can be heat treated to enhance their ultimate tensile strength and yield stress.

To achieve these enhancements, profiles are put into ovens where their aging process is accelerated and they are brought to the T5 or T6 tempers.


How do their properties change? As an example, untreated 6061 aluminum (T4) has a tensile strength of 241 MPa (35000 psi). Heat-treated 6061 aluminum (T6) has a tensile strength of 310 MPa (45000 psi).

It is important for the customer to understand the strength needs of their project to ensure the right choice of alloy and temper.

After heat treating, profiles can also be finished.

Surface Finishing: Enhancing Appearance and Corrosion Protection

The two main reasons to consider these is that they can enhance the appearance of the aluminum and can also enhance its corrosion properties. But there are other benefits as well.


For example, the process of anodization thickens the metal's naturally-occurring oxide layer, improving its corrosion resistance and also making the metal more resistant to wear, improving surface emissivity, and providing a porous surface that can accept different colored dyes.

Other finishing processes such as painting, powder coating, sandblasting, and wood grain transfer (to create a wood look), can be undergone as well.

Fabrication: Machining Final Dimensions

Fabrication options allow you to achieve the final dimensions that you are looking for in your extrusions.

Profiles can be punched, drilled, machined, cut, etc. to match your specifications.


For example, the fins on extruded aluminum heatsinks can be cross machined to create a pin design, or screw holes can be drilled into a structural piece.

Regardless of your requirements, there is a wide range of operations that can be performed on aluminum profiles to create the perfect fit for your project.

Summary: Aluminum Extrusion is an Important Manufacturing Process

Aluminum extrusion is a process for creating parts with specific cross-sectional profiles by pushing heated alloy material through a die.

Shapes created can be solid, hollow, non-standard,heat sink and semi-hollow; and they can be simple or they can be complex.

Extrusion is a fascinating technique that produces 4-to-24-foot-long profiles that can then be heat treated, polished, and manufactured according to customer specifications. 

If you would like further information on how to optimize the design of your item for the extrusion process, you can contact us via E-mail or online service.