Aluminum Extrusion Service

  • Multi-axis CNC post-machining
  • Delivery in 2-3 Weeks
  • Low cost from 1 to 1000+ Part
  • Highly accurate with excellent surface finish
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Aluminum Extrusion Capabilities

Direct Aluminum Extrusion

Direct extrusion, often called forward extrusion, is the most common metal extrusion method. With Direct extrusion, a high-pressure ram propels a material billet through a container. The material moves along the ram’s path, emerging through the stationary die’s opening. This method can be used for substantial-profile designs and yields superior surface finishes compared to indirect extrusion.

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Indirect Aluminum Extrusion

With indirect extrusion, the material is placed into a container and secured. The extrusion die moves with a hollow ram over the material, forcing it through the die opening. Since there is no relative movement between the material and container, there is much less friction with this method, resulting in greater control over dimensional consistency, material properties, and grain size when compared with direct extrusion.

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Our Services

At KUSLA Prototype, we provide high-quality, cost-effective, and fast aluminum extrusion services for various industries and applications. We can help you design and manufacture aluminum extrusion profiles with complex shapes and sizes, using different grades of aluminum alloys.

We also offer CNC machining, finishing, and assembly services to ensure the accuracy and functionality of your extruded parts. Whether you need aluminum extrusions for aerospace, construction, electronics, medical, sports, or telecommunications.

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Low Volume Manufacturing

Flexible, cost-effective low-volume manufacturing for 10-100,000 units. Minimize risk, accelerate time-to-market, and optimize production costs. Agility and quick turnaround for on-demand manufacturing.

Rapid Prototyping

Rapid prototyping is a process used in product development to quickly create physical prototypes of a design or concept. It involves using specialized techniques, tools,…

Aluminum Extrusion prototyping

Our Rapid Aluminum Extrusions process offers Prototype Extrusions in as little as 3 weeks. The main advantage of our Rapid Extrusion process is the ability to create Prototype Extrusions with very complex cross sections. Rapid Cut offers extrusions in Aluminum 6061 and 6063 in a variety of lengths and profiles

Low Volume Aluminum Extrusion

We take pride in offering a specialized solution for low-volume aluminum extrusion. Our service is tailored to meet the unique needs of clients seeking small-batch production of high-quality aluminum profiles. Whether you require custom-designed components, prototypes, or limited production runs, our expertise and equipment ensure precision, flexibility, and cost-effectiveness.

Custom Aluminum Extrusion Profiles

Custom aluminum extrusion profiles can be cut to any 2D cross-sectional shape.  KUSLA custom manufacturing services enable you to get extruded parts made with custom extrusion profiles. If you are looking to save cost and time by post-machining an existing aluminum extrusion profile, we can make it happen.

Standard profiles include:

  • Circular bar
  • Square bar
  • Circular tube
  • Square tube
  • L-shape
  • U-shape 
  • T-shape
  • C-shape
  • J-shape
  • F-shape
High-Quality and Fast Aluminum Extrusion Services for Diverse Industries

What is Aluminum Extrusion?

Aluminum Extrusion is kind of process how aluminum is shaped. An extrusion is produced by pushing an aluminum billet heated to 600 degrees Celsius through a steel die. The result in the extruded material emerging as a perfectly replicated cross-section of the die pattern.

Aluminum Extrusion Specification

  • Press sizes: 450T ~ 3000T
  • Tooling lead time: 2 weeks for small molds, 4 weeks for larger molds.
  • Post-machining: Full-service CNC cutting, threading, slotting, face milling, etc.
  • Tolerances: follow NADCA tolerances

Benefits Of Aluminum Extrusion

  • Cost-efficient
  • Operational flexibility
  • easy post-machining
  • Continuous production
  • Suitable for high production volumes
  • Compatible with a variety of raw materials
  • Effective compounding for material mixing
  • Achieves a favorable surface finish

Materials for Aluminum extrusion

  • Aluminum 1100 —Could be extruded into intricate shapes with an excellent brilliant finish.
  • Aluminum 3003 —The alloys in the 3000 series are typically exclusively extruded for heat exchanger tubes.
  • Aluminum 6063 — Suitable for ornamental applications with a good surface finish or difficult-to-extrusion features like thin walls or fine detailing.
  • Aluminum 6061 —can be used as a structural staple in the transportation and machined parts industries. a good choice for welded structural members like vehicles, trucks, trailer frames, railroad cars, and pipelines.

Surface finishing for aluminum extrusion parts

  • Painting can be used to finish metal sheet parts.
  • Powder coating involves applying a dry powder paint to the parts, which is then baked onto the part. This method is often used for parts that need to be used in a harsh environment.
  • Anodizing creates a durable, corrosion-resistant finish on aluminum parts. This is a chemical and electrical process which causes a thin oxide layer to form on the surface of the parts.
  • Plating: Extruded parts can be plated with electroless nickel, nickel, brass, tin, chrome, chromate, Teflon, silver, and gold.

Surface Finishing

Enhance product durability and visual appeal with our expert surface finishing services. From polishing to coating, we offer a wide range of specialty options to meet your needs for rapid…
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Service Workflow 

Send Us Your CAD File

Send Us Your CAD

Fill in your info and send CAD file. We’ll create a 3D model for your part/prototype

Quote & Design Analysis

Quote & Design Analysis

In 24 hours, you’ll get a quote and DFM feedback for project feasibility and cost estimates.

Order & Start CNC Machining

Order & Start Machining

Once you place your order, we will begin production of your CNC prototype or CNC machined part.

Dimension Check & Test

Quality Check

We measure parts’ dimensions with calipers, micrometers, gauges, or CMMs.

Packaging & Shipping

Packaging & Shipping

We pack and ship your products with a robust international express standard.

Other capability You May Like to Know

Sheet Metal Fabrication

Experience superior sheet metal fabrication services at KUSLA Prototype. We offer cutting, bending, welding, and more for aluminum, steel, copper, and brass materials. Get a free quote today!

Aluminum Die Casting

Experience top-quality aluminum die casting services for various industries. Our expertise, advanced techniques, and competitive pricing ensure accurate and durable products. Request a quote today!

Rapid Tooling

Achieve success with KUSLA Prototype’s high-quality and cost-effective rapid tooling services. Fast turnaround, advanced technology, and skilled engineers for your product development needs.

CNC Aluminum Machining

Experience precise and efficient CNC aluminum machining services. Our skilled team utilizes advanced technology to deliver high-quality results for your manufacturing needs.

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FAQs About Aluminum extrusion

For extrusion applications, aluminum 6063 is a great option. It has good extrudability and can form complex shapes. But if you need more strength, aluminum 6061 is better. It has higher mechanical properties than 6063 and can handle more stress.

Castings are limited to metals with low melting points, such as aluminum, magnesium, and copper, have higher initial tooling costs, and mold life can be short. Extrusions are a better option in shorter production runs due to lesser start-up costs. Castings, unlike extrusions, are not constrained by sizes.