Aluminum Extrusion Quick Start Guide
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.
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.
PART SIZE
The parts we manufacture need to fit inside of a 3.50” – 4.00” diameter circle
MINIMUM WALL THICKNESS
| Alloy | Minimum Wall Thickness |
| 3003 | .020” |
| 6063 | .025” |
| 6061 | .030” |
| Alloy | Minimum Wall Thickness |
| 3003 | .020” |
| 6063 | .025” |
| 6061 | .030” |
EXTRUSION TYPES
UNIFORM WALL THICKNESS
Uniform wall thicknesses are less costly to extrude
ROUNDED FILLETS & CORNERS
Rounded corners & fillets are easier to extrude than sharp ones.
JOINING METHODS
TONGUE RATIO
Easy / 3:1 Ratio
Challenging / 5:1 Ratio
Extremely Difficult / 8:1 Ratio
SYMMETRY
Symmetrical parts are easier to extrude
TOOLING COSTS
| Shapes Type | Average Cost | Lead Time |
| Solid | $750 | 3-4 Weeks |
| Semi Hollow | $1350 | 3-4 Weeks |
| Hollow | $1850 | 4-5 Weeks |
LEAD TIMES
Typical Lead Time for Mill Finish Extrusions: 5-6 weeks (as of November 2022)
| Process | Additional Lead Time |
| Cut-to-Length or Deburr | 2 Weeks |
| Anodize | 3 Weeks |
| Machining | 3-4 Weeks Depending on complexity |
| Process | Additional Lead Time |
| Cut-to-Length or Deburr | 2 Weeks |
| Anodize | 3 Weeks |
| Machining | 3-4 Weeks Depending on complexity |
