Aluminum extrusions can be produced in an almost endless variety of geometries and sizes. Miniature extrusions, our specialty, have been successfully produced which measured only .100” wide. The largest extrusions are up to 36” wide. Extruded aluminum designs can be solid or hollow, and many designs have multiple voids. Each of the three designs require a different aluminum extrusion die design. Profile Precision Extrusions works closely with the best die manufacturers in our industry to develop the extrusion dies necessary to successfully produce our customers’ aluminum extrusion designs.
Solid Dies
Extrusion dies for solid rods, bars, angles and tees are the simplest to produce and are less costly. They are produced using H13 tool steel. A combination of wire EDM and CNC machining cut the design into the steel. The cost of a solid die typically runs around $900 and takes four weeks to build.
Hollow Dies
Extrusion dies for round tubes, rectangular tubes, and other hollow designs require a 2-piece die. The die housing supports the mandrel which forms the inside surface of a tube. The die plate is the second piece and it forms the outside of the tube. The cost for hollow dies is between $1,500 – $2,000. Due to the added complexity of manufacturing two pieces that must fit together, a hollow die takes five weeks to build on average.
Multi-void Dies
The most complicated, and expensive extrusion dies, are for multi-void hollow designs. It is not unusual for an extruded aluminum design to have three or four voids. These dies can run from $2,000 – $2,500. It is also possible to construct an extrusion die with more than 10 voids. These types of designs are the most challenging for the supplier. The designer should work very closely with their supplier to optimize the design and alloy choice. The cost of these types of dies can run $5,000 and more.
Profile Precision Extrusions has run almost 5,000 designs in the past 20 years. One of our earliest dies, copy #177 had 26 voids. In 2021 we extruded a design with 61 voids! To learn more, visit our website for aluminum extrusion design tips. If you’re new to aluminum extrusion design, download our free eBook below, 7 Steps to Bring Your Aluminum Extrusion to Life. Contact or call us today at 623.936.5599.
