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ISO9001:2008 Registered

Extrusion Design Tips

Part Size
The parts we manufacture need to fit in a 3.50” circle

circle

Minimum Wall Thickness:

ALLOY

MINIMUM WALL THICKNESS

3003

.020”

6063

.025”

6061

.030”

 

Extrusion Types  

Solid Semi Hollow    Hollow
Solid Extrusion Example Semi Hollow Extrusion Example Hollow Extrusion Example
                                                                                       

Uniform Wall Thickness
Uniform wall thicknesses are less costly to extrude

Uniform Wall ThicknessNon-Uniform Wall Thickness

 

Rounded Fillets & Corners
Rounded corners and fillets are less costly to extrude

Round Corners Extrusion ExamplesRounded Corners Extrusion Examples

Joining Methods

Dovetail Interlock Sliding Fit
dovetail interlock slide fit

 

Tongue Ratio

Easy Challenging Extremely Difficult
3:1 Ratio 5:1 Ratio 8:1 Ratio
Tongue Ratio 3:1 Extrusion Example Tongue Ratio 5:1 Extrusion Example Tongue Ratio 8:1 Extrusion Example

Symmetry
Symmetrical parts are easier to extrude

Symmetry Extrusion ExampleNonSymmetry Extrusion Example


Critical Dimensions
Be sure to identify the 1-2 most critical dimensions, and tolerances required

Cosmetic Surfaces
Be sure to identify the surfaces that are cosmetically important

Tooling Costs

Shape Type

Average Cost

Lead Time

Solid

$550

2 weeks

Semi Hollow

$1150

2-3 weeks

Hollow

$1350

3 weeks

Lead Times
Typical Lead Time for Mill Finish Extrusions: 3 weeks

Process

Additional Lead Time

Cut-To-Length or Deburr

1 week

Anodize

1 week

Machining

1-2 weeks depending upon complexity

               
Aerospace Alloys
2014, 2024, 7075 & 7050 require special processing and heat treating. We have a limited capability to extrude and process these alloys. If we cannot extrude your design due to our capabilities we will be happy to give you a referral.