The Right Extrusion Design Matters
The design of your aluminum extrusion directly impacts strength, weight, manufacturability, and cost. While standard profiles can work for simple applications, many projects require custom extrusion shapes to meet performance, tolerance, and functional requirements.
At Profile Precision Extrusions, we work with engineering and manufacturing teams to evaluate shape options early — helping ensure your design is both functional and manufacturable.
Shape Complexity
Basic
Simple I-beam profile
Complex
Multi-void custom profile
Sold VS Hollow
Solid
Maximum Strenght
Hollow
Reduced Weight
Standard vs. Custom
Custom vs. Standard Extrusion Shapes
Understanding when to use custom profiles versus standard shapes can significantly impact your project’s performance, cost, and production timeline.
Custom Shapes
Engineered for your application
Engineered profiles designed for specific applications. Tailor-made for improved performance and the ability to meet tight tolerances or complex design requirements.
- Designed for your exact requirements
- Tighter tolerances achievable
- Optimized for performance & weight
- Supports complex multi-void geometries
- The cost of a custom extrusion die is no more than that of a standard shape die
Standard Shapes
Off-the-shelf profiles
Readily available profiles with lower upfront cost and faster initial setup. Best suited for simple applications where design flexibility is not critical.
- Faster initial setup
- Lower tooling cost
- Works for simple applications
- Limited design flexibility
Most PPE projects involve custom-designed shapes to meet precise performance and manufacturing needs.
Not sure how to design a custom shape? Talk to our team →
capabilities
Extrusion Design Criteria and Capabilities
Our capabilities are optimized for small, precise, and thin wall extrusion profiles.
Aluminum Alloys
- 6061, 6063, 3003, 1100 are regularly produced.
- 2024 and 7075 may be available for very small solid shapes.
- Additional alloys can be considered upon request.
Size Capabilities
- Up to 4” circle size for solid shapes.
- Up to 2.5” circle size for round tubing.
Tolerances
- Up to half of standard commercial aluminum tolerances.
- Tight control of bow, twist, and straightness.
- Wall thickness as thin as 0.020”*
(*dependent upon geometry and alloy desired).
Fabrication & Machining
- CNC machining
- Drilling, milling, and countersinking
- Precision cutting
- Deburring and finishing support
Finishing Options
- Clear and color anodizing (Type II)
- Hard coat anodizing (Type III)
- Chem film (clear and yellow, RoHS compliant)
- Powder coating
Why PPE
Built for Small, Complex, and Tight-Tolerance Profiles
Many extrusion providers focus on larger, high-volume profiles. PPE specializes in smaller, more complex shapes that require precision and consistency.
Our team works closely with engineers to ensure designs are optimized for both performance and manufacturability — reducing risk before production begins.
Expertise in miniature extrusions
We Specialize in profiles other manufactures call impossible – complex geometries, tiny cross-sections, and demanding tolerances.
Tight tolerance control
Up to half of commercials tolerances. Bow twist, and straightness controlled to exacting standards across every run.
U.S.-based manufacturing
All design, tooling, and production takes place in Phoenix, A.Z. No overseas handoffs, no communiation gaps.
Engineering Collaboration
We work alongside your team from concept through production – optimizing designs before they reach the floor.
next steps
Continue Your Design Process
Explore the next steps in developing your aluminum extrusion and move your project forward with confidence.
Design Guide
Learn how to design alumninum extrusion profiles for manufacturability. tolerance, and performance from the start.
Prototyping
Validate your design before committing to full production. Our prototyping process reduces risk and confirm performance.
Custom Extrusions
Understand your options and capabilities for fully engineered, application-specific aluminum extrusion profiles.
Start Your Aluminum Extrusion Prototype
Have a design or idea in mind? Our team will help you evaluate shape options, manufacturability, and next steps – from concept through production.
