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Aluminum Extrusion Machining
Professional Aluminum Extrusion Machining Services
Aluminum extrusions are subject to precision CNC machining with tolerances to ±0.001″. Our company has over 25 years of experience serving aerospace, automotive, and industrial applications.
Our Services
Full-Scale Aluminum Extrusion Machining Services
We handle everything from prototyping to mass production and offer precision machined aluminum extrusion parts capable of fulfilling the strictest requirements.
CNC Milling
Offering high-precision 3, 4, and 5-axis CNC milling for intricate aluminum profiles. Ideal for aerospace and auto body parts.
- 5-axis simultaneous machining
- Profile length capacity of 20′
- Positioning accuracy of ±0.001″
Drilling & Tapping
CNC-controlled accurate drilling and tapping with strict tolerance on hole patterns ensuring perfect repeatability.
- Multiple-spindle drilling heads
- Thread sizes #2-56 to 1″-8
- Automated hole pattern programming
Sawing & Cutting
Precision cutting with burr-free edges. Includes cutting off and miter cuts for complex frame assemblies.
- Automatic length gauging
- Miter capability from 0° to 60°
- Batch cutting of 1000 pcs/hr
Notching & Punching
Specific notching and punching operations for T-slot aluminum framing, window profiles, and structural applications.
- 30-ton CNC punch press capacity
- Custom die making included
- In-line deburring option available
Secondary Operations
Full finishing services such as deburring, anodizing prep, assembly, and quality control.
- Vibratory deburring included
- Manual and automated assembly
- 100% dimensional inspection
Custom Fixturing
In-house digital rendering and fixture manufacturing for complex profiles, ensuring near-zero distortion.
- CAD/CAM fixture design
- Vacuum and mechanical clamping
- Quick-change production systems
Gallery of Custom Aluminum Extrusion Machining Parts
Explore our gallery of custom aluminum extrusion machining parts. We specialize in creating high-quality, precision-engineered components tailored to your specifications.
Technical Capabilities
Precision Machining Capabilities for Aluminum Extrusions
The highly equipped facility is a home to more than 50 explicitly CNC machines for aluminum extrusion machining. Each project is a challenge, but we have the right tools and professionals for it, no matter if it is just a simple cutoff or complex 5-axis contouring.
01
5-Axis CNC Machining Centers
Simultaneous 5-axis capability for complex contours, aerospace stringers, and compound-angle features without repositioning.
02
Long Profile Machining
Dedicated equipment for aluminum extrusions up to 40 feet in length with continuous machining capability.
03
Thin-Wall Expertise
Specialized fixturing and tooling strategies to machine walls as thin as 0.040″ without distortion.
04
High-Speed Machining
Spindle speeds up to 24,000 RPM for superior surface finishes and reduced cycle times on aluminum.
Machine Specifications
Travel (X/Y/Z)
120″ × 40″ × 30″
Spindle Speed
Up to 24,000 RPM
Positioning Accuracy
±0.0001″
Repeatability
±0.00005″
Max Profile Length
40 feet (480″)
Surface Finish
16 Ra µin standard
Tool Capacity
60+ tools per machine
⚙️ CNC Tools
Aluminum Extrusion Machining Calculator Suite
Professional CNC cutting parameters, cycle time estimation, and tap drill reference for aluminum extrusion machining.
Input Parameters
End Mill
Drilling
Face Mill
in
in
in
Calculated Parameters
Spindle Speed
6,112 RPM
Feed Rate
92 IPM
Chip Load
0.005 IPT
Material Removal
5.75 in³/min
Formulas Used
RPM = (SFM × 12) ÷ (π × D)
Feed = RPM × Flutes × Chip Load
MRR = Feed × Ap × Ae
Feed = RPM × Flutes × Chip Load
MRR = Feed × Ap × Ae
Cutting Speed Reference (SFM)
| Alloy | Hardness | HSS (SFM) | Carbide (SFM) | Chip Load (IPT) |
|---|---|---|---|---|
| 6061-T6 | 95 HB | 300-600 | 800-1500 | 0.003-0.008 |
| 6063-T5 | 60 HB | 400-700 | 1000-2000 | 0.004-0.010 |
| 7075-T6 | 150 HB | 250-400 | 600-1200 | 0.002-0.006 |
| 2024-T3 | 120 HB | 300-500 | 700-1400 | 0.003-0.007 |
Operation & Parameters
Milling
Drilling
Facing
Pocketing
in
IPM
sec
in
IPM
sec
in
in
in
IPM
sec
in
in
in
in
IPM
Time Estimate
Cycle Time per Part
1.40 min
Cutting Time
0.90 min
Load/Unload
0.50 min
Parts/Hour
43
Efficiency
64%
Total Run Estimate
Machine Time
2.33 hours
With Setup (30 min)
2.83 hours
| Thread | TPI | Major Dia. | Tap Drill (75%) | Decimal | Clearance |
|---|---|---|---|---|---|
| #4-40 | 40 | 0.112″ | #43 | 0.089″ | #31 |
| #6-32 | 32 | 0.138″ | #36 | 0.107″ | #25 |
| #8-32 | 32 | 0.164″ | #29 | 0.136″ | #17 |
| #10-24 | 24 | 0.190″ | #25 | 0.150″ | #7 |
| 1/4″-20 | 20 | 0.250″ | #7 | 0.201″ | F |
| 5/16″-18 | 18 | 0.313″ | F | 0.257″ | P |
| 3/8″-16 | 16 | 0.375″ | 5/16″ | 0.313″ | W |
| 1/2″-13 | 13 | 0.500″ | 27/64″ | 0.422″ | 33/64″ |
| 5/8″-11 | 11 | 0.625″ | 17/32″ | 0.531″ | 41/64″ |
| 3/4″-10 | 10 | 0.750″ | 21/32″ | 0.656″ | 49/64″ |
| Thread | TPI | Major Dia. | Tap Drill (75%) | Decimal | Clearance |
|---|---|---|---|---|---|
| #4-48 | 48 | 0.112″ | #42 | 0.094″ | #31 |
| #6-40 | 40 | 0.138″ | #33 | 0.113″ | #25 |
| #10-32 | 32 | 0.190″ | #21 | 0.159″ | #7 |
| 1/4″-28 | 28 | 0.250″ | #3 | 0.213″ | F |
| 5/16″-24 | 24 | 0.313″ | I | 0.272″ | P |
| 3/8″-24 | 24 | 0.375″ | Q | 0.332″ | W |
| 1/2″-20 | 20 | 0.500″ | 29/64″ | 0.453″ | 33/64″ |
| Thread | Pitch | Major Dia. | Tap Drill (75%) | mm | Clearance |
|---|---|---|---|---|---|
| M3 × 0.5 | 0.5 mm | 3.0 mm | 2.5 mm | 2.50 | 3.2 mm |
| M4 × 0.7 | 0.7 mm | 4.0 mm | 3.3 mm | 3.30 | 4.3 mm |
| M5 × 0.8 | 0.8 mm | 5.0 mm | 4.2 mm | 4.20 | 5.3 mm |
| M6 × 1.0 | 1.0 mm | 6.0 mm | 5.0 mm | 5.00 | 6.4 mm |
| M8 × 1.25 | 1.25 mm | 8.0 mm | 6.8 mm | 6.80 | 8.4 mm |
| M10 × 1.5 | 1.5 mm | 10.0 mm | 8.5 mm | 8.50 | 10.5 mm |
| M12 × 1.75 | 1.75 mm | 12.0 mm | 10.2 mm | 10.20 | 13.0 mm |
| M16 × 2.0 | 2.0 mm | 16.0 mm | 14.0 mm | 14.00 | 17.0 mm |
Thread Engagement
75% engagement is standard. For aluminum, this provides excellent holding power without risk of tap breakage.
Aluminum Tapping Tips
Use spiral flute taps for blind holes, spiral point for through holes. Always use cutting oil to prevent galling.
Tap Drill Formula
Tap Drill = Major Dia. – (1/TPI × % Engagement). For 75%: Tap Drill ≈ Major Dia. – 0.75/TPI
Industries Served
Precision Aluminum Extrusion Machining for Every Industry
Our precision aluminum extrusion machining services support critical applications across diverse industries, each with unique requirements and certifications.
Applications in Aerospace
AS9100D certified machining for wing spars, seat rails, floor beams, and structural stringers from 7075 and 2024 aluminum extrusions.
- Wingspar machining to +/- 0.002″
- 7075-T6 and 2024-T3 alloys
- Full material traceability
Battery Enclosure for EVs
High-speed machining of 6063 extrusions for EV battery trays, cooling channels, and crash structures.
- Battery tray frame machining
- Thermal management profiles
- Groundwater to IATF 16949 thresholds
Heat Sink Fabrication
Precision machining of finned extrusions for LED lighting, power electronics, and server applications.
- Fin pitch of as low as 1mm
- Flatness to 0.002″ per inch
- Thermal interface prep
🔬 Engineering Tools
Aluminum Material Hub
Comprehensive material selection, weight calculation, hardness conversion, and thermal expansion tools for aluminum extrusion machining.
6061-T6
6000 Series
Tensile Strength
45 ksi / 310 MPa
Yield Strength
40 ksi / 276 MPa
Hardness
95 HB
Density
0.098 lb/in³
6063-T5
6000 Series
Tensile Strength
27 ksi / 186 MPa
Yield Strength
21 ksi / 145 MPa
Hardness
60 HB
Density
0.097 lb/in³
7075-T6
7000 Series
Tensile Strength
83 ksi / 572 MPa
Yield Strength
73 ksi / 503 MPa
Hardness
150 HB
Density
0.101 lb/in³
2024-T3
2000 Series
Tensile Strength
70 ksi / 483 MPa
Yield Strength
50 ksi / 345 MPa
Hardness
120 HB
Density
0.100 lb/in³
5052-H32
5000 Series
Tensile Strength
33 ksi / 228 MPa
Yield Strength
28 ksi / 193 MPa
Hardness
60 HB
Density
0.097 lb/in³
6082-T6
6000 Series
Tensile Strength
47 ksi / 324 MPa
Yield Strength
42 ksi / 290 MPa
Hardness
95 HB
Density
0.098 lb/in³
Input Parameters
Rect Bar
Round Bar
Round Tube
Square Tube
in
in
in
Calculated Weight
Weight per Piece
2.35 lbs
Total Weight
2.35 lbs
Metric
1.07 kg
Cross Section
2.00 in²
Per Foot
2.35 lb/ft
Enter Hardness Value
Brinell (HB)
95
500 kgf, 10mm ball
Rockwell B (HRB)
60
1/16″ ball, 100 kgf
Vickers (HV)
106
Diamond pyramid
Tensile (ksi)
45
Approximate
| Alloy | HB | HRB | HV | UTS (ksi) |
|---|---|---|---|---|
| 6061-T6 | 95 | 60 | 107 | 45 |
| 6063-T5 | 60 | 42 | 67 | 27 |
| 7075-T6 | 150 | 87 | 175 | 83 |
| 2024-T3 | 120 | 75 | 137 | 70 |
| 5052-H32 | 60 | 41 | 67 | 33 |
Input Parameters
Calculated Results
Temperature Change (ΔT)
82 °F
(45.6 °C)
Length Change (ΔL)
0.0129 in
(0.328 mm)
New Length
12.0129 in
(305.13 mm)
Expansion Rate
1,070 ppm
Our Process
How Our Aluminum Extrusion Machining Process Works
Every aluminum extrusion machining project will have quality, communication, and on-time delivery thanks to our streamlined process from initial quote to final delivery.
01
Submit Your Requirements
Submit CAD files (STEP, IGES, DXF) or drawings. Your aluminum extrusion specifications will be reviewed by our engineering team in less than 24 hours.
02
DFM Analysis & Quote
Obtain thorough Design for Manufacturability feedback and competitive pricing. We will recommend changes that will lower costs without compromising quality.
03
Engineering & Programming
The CAM programmers design optimized toolpaths while the fixture designers develop custom solutions for workholding your aluminum extrusion profiles.
04
Precision Machining
CNC equipment of the highest quality is used for your parts, and the in-process inspection maintains the tight tolerances throughout the whole production.
05
Quality Inspection
CMM and optical measurement systems are used for 100% dimensional inspection. Complete documentation including first article inspection reports (FAIR).
06
Delivery & Support
Each part is put in a strong box and marked ‘fragile’ to avoid damage. Follow shipment live. Your team is ready to assist with production support.
📐 QC Tools
Tolerance & Surface Finish Center
Comprehensive tolerance standards, ISO fits calculation, surface finish conversion, and anodizing specifications for precision aluminum machining.
| Nominal Size Range | Standard (±) | Precision (±) | High Precision (±) |
|---|---|---|---|
| Up to 1.000″ | ±0.012″ | ±0.005″ | ±0.002″ |
| 1.001″ – 2.000″ | ±0.015″ | ±0.007″ | ±0.003″ |
| 2.001″ – 4.000″ | ±0.020″ | ±0.010″ | ±0.004″ |
| 4.001″ – 8.000″ | ±0.025″ | ±0.012″ | ±0.005″ |
| 8.001″ – 12.000″ | ±0.030″ | ±0.015″ | ±0.006″ |
Note: Based on ASTM B221 for aluminum extrusions. Tighter tolerances may require secondary machining operations.
| Feature | Standard | Precision |
|---|---|---|
| Angular Tolerance | ±1° | ±0.5° |
| Perpendicularity | ±1° per inch | ±0.5° per inch |
| Parallelism | 0.003″ per inch | 0.001″ per inch |
| Surface Area | Standard | Precision |
|---|---|---|
| Up to 4 sq. in. | 0.005″ | 0.002″ |
| 4 – 16 sq. in. | 0.008″ | 0.003″ |
| 16 – 36 sq. in. | 0.012″ | 0.005″ |
| Over 36 sq. in. | 0.015″ | 0.008″ |
| Nominal Wall | Tolerance (±) |
|---|---|
| Up to 0.062″ | ±0.006″ |
| 0.063″ – 0.125″ | ±0.008″ |
| 0.126″ – 0.250″ | ±0.010″ |
| Over 0.250″ | ±0.012″ |
ISO Fit Calculator
Quick Fit Selection
Calculated Dimensions
CLEARANCE FIT
H7/h6
Clearance: 0 to +0.046 mm
Hole (H7)
Maximum
25.021 mm
Minimum
25.000 mm
Shaft (h6)
Maximum
25.000 mm
Minimum
24.987 mm
Surface Finish Converter
Ra (Microinch)
63
µin
Ra (Micrometer)
1.6
µm
Rz (Micrometer)
6.3
µm
RMS (Microinch)
70
µin
Surface Finish Reference Guide
Rough Machining
Ra 125-250 µin (3.2-6.3 µm)
As-machined, rough turning, milling
Standard Finish
Ra 63-125 µin (1.6-3.2 µm)
General machining, typical CNC finish
Fine Finish
Ra 32-63 µin (0.8-1.6 µm)
Precision machining, close tolerance
Very Fine / Ground
Ra 8-32 µin (0.2-0.8 µm)
Ground surfaces, bearing surfaces
Mirror / Polished
Ra 2-8 µin (0.05-0.2 µm)
Polished, lapped, optical surfaces
Type I
Decorative
MIL-A-8625 Type I – Chromic Acid
Thin coating for applications where fatigue strength is critical. Best for tight tolerance parts requiring minimal dimensional change.
Thickness
0.02-0.3 mil
Hardness
300-400 HV
Color
Gray
Penetration
~50%
Type II
Standard
MIL-A-8625 Type II – Sulfuric Acid
Most common anodizing type. Good corrosion resistance with excellent dyeing capability for colored finishes.
Thickness
0.1-1.0 mil
Hardness
400-600 HV
Color
Dyeable
Penetration
67% / 33%
Type III
Hardcoat
MIL-A-8625 Type III – Hard Anodize
Maximum wear resistance and surface hardness. Ideal for high-wear applications but adds significant thickness.
Thickness
1.0-4.0 mil
Hardness
60-70 HRC
Color
Dark Gray/Black
Penetration
50% / 50%
Dimensional Impact on Tolerances
Important: Anodizing both builds up on the surface AND penetrates into the base material. Account for this when specifying tight tolerances on critical features.
| Anodize Type | Per Surface Build-up | Hole Shrinkage (Dia.) | Shaft Growth (Dia.) |
|---|---|---|---|
| Type I (Chromic) | 0.0001-0.00015″ | 0.0002-0.0003″ | 0.0002-0.0003″ |
| Type II (Sulfuric) | 0.0002-0.0008″ | 0.0004-0.0016″ | 0.0004-0.0016″ |
| Type III (Hardcoat) | 0.001-0.002″ | 0.002-0.004″ | 0.002-0.004″ |
Project Case Studies
// Select a project to view technical detailsEV Battery Tray Machining
The Challenge
Machining large-format 6063-T6 extrusions (2,100mm) with intricate internal cooling channels. Key hurdles included maintaining ±0.2mm flatness over the large surface and managing distortion in 1.5mm thin-wall sections.
Our Solution
- Fixture: 48-zone vacuum system for uniform clamping.
- Parameters: 18,000 RPM spindle, 70-bar high-pressure coolant.
- Quality: 100% CMM inspection & real-time SPC tracking.
| Metric | Achievement |
|---|---|
| Accuracy | 99.7% (±0.05mm) |
| Flatness | ±0.15mm (Exceeded Spec) |
| Scrap Rate | Reduced to 0.6% |
| Cycle Time | 18.5 mins (-35%) |
“Innovative solutions improved quality and efficiency. Their IATF 16949 certification gave us complete confidence.”
— Senior Mfg Engineer, EV OEM
Aerospace Wing Spar
The Challenge
Machining 7075-T6 extrusion components for commercial aircraft wings. Required AS9100D certification, full traceability, and strict control over surface finish on complex 5-axis geometries.
Our Solution
- Strategy: 5-Axis spiral toolpaths to manage spindle engagement.
- Tooling: Variable-helix DLC coated carbide to stop vibration.
- Verification: 156-point check per piece with Zeiss Contura CMM.
| Standard | Result |
|---|---|
| FAI Approval | First Pass Yield |
| Surface Finish | Ra 0.65μm (Spec: 0.8) |
| Position Tol | 100% within ±0.025mm |
| Quality Escapes | 0 NCRs in 3 Years |
“A supplier who understands aerospace aluminum. Their technical capability on 7075 makes them our clear choice.”
— Supply Chain Mgr, Aerospace Tier-1
High-Performance Heat Sink
The Challenge
Developing 350kW charging module heat sinks from 6061-T6. Critical need to protect 42 delicate fins (2mm thick) while achieving 0.05mm base flatness for thermal transfer.
Our Solution
- Workholding: Custom soft-jaws with polyurethane inserts.
- Process: Multi-stage stress relief stabilization sequence.
- Finishing: Climb milling with wiper inserts at 20°C constant temp.
| Metric | Outcome |
|---|---|
| Base Flatness | 0.035mm (Avg) |
| Fin Damage | 0.2% (Ind Avg: 3-5%) |
| Thermal Perf | 100% Pass Rate |
| Lead Time | Cut to 3 Weeks |
“The difference was their understanding of thermal and mechanical dimensions. Consistent thermal performance achieved.”
— Hardware Engineering Director
Auto Crash Management
The Challenge
JIT production of 6061-T6 crash boxes. Safety-critical requirements meant zero defects allowed on structural integrity while maintaining high volume (800 sets/week).
Our Solution
- Automation: 4-machine robotic cell with auto pallet changers.
- Safety: In-process probing & tool wear monitoring.
- Logistics: VMI program integrated with client MRP.
| Metric | Outcome |
|---|---|
| Crash Test | 100% Success |
| Delivery | 99.8% On-Time |
| Quality (PPM) | 12 PPM (Target <50) |
| Volume | 165k Sets / 4 Yrs |
“With components that protect occupants, trust is critical. Their expertise is why they are our top NA supplier.”
— Global Purchasing Director
Aluminum Extrusion Machining Parts FAQs
Aluminum extrusion machining process primary comes from a profile that has been extruded to the exact cross-section shape. The extrusion parts are marked and cut with the help of a fixture on CNC or a machining center. After that, the pieces are machined by means of milling, drilling, sawing, or turning. Additionally, the computer numerical control (CNC) system controls the operation of high-speed mills and cutters to achieve accuracy and meet tight tolerances. Finished parts undergo secondary operations, such as surface finishing and coating, to prepare them for assembly, with deburring or anodizing used as necessary.
Using an extrusion machining center means precision processing of the most complex geometries and top aluminum parts. It allows custom aluminum profiles to be made to exact measurements; it does not require assembly because the ready-to-install extrusion parts are preassembled, thereby improving manufacturability. The use of CNC technology, along with dedicated tooling, leads to less time taken for setup, and this makes it possible to produce custom aluminum profiles at a lower cost and with more consistent repeatability and precision.
Absolutely, machining centers and CNC machines can deliver the required precision for aerospace and other demanding industries. A manufacturer can mill aluminum alloys such as 6061 or even tougher 7000 series with precision and no deformation by using the correct tools, jigs, and tight process control systems. Lubrication, tool selection, and process parameters determine whether the surface finish and corrosion resistance meet aerospace standards.
The most typical machining operations are milling, drilling, tapping, sawing, turning, and deburring. Horizontal machining and rotary operations on machining centers are often used to produce complex forms and specific cross-sectional profiles. The secondary processes, like cutting-to-length with saws, anodizing, or powder coating, complete the workflow. These processing steps allow the fabrication of extrusion parts with tight tolerances and desired surface finishes.
The manufacturability of parts depends on the extrusion process, the alloy selected, and the design of the cross-sectional profiles. For instance, alloys such as 6061 have a higher ease of machining and also possess good properties like corrosion resistance and recyclability, though the 7000 series alloys provide better strength-to-weight ratio, albeit with the requirement of specific tooling. It is crucial for designers to be aware of wall thickness, support for work-holding, and the allowances for machining in order to not have the parts deform and also to be able to produce high-quality aluminum parts in the most cost-effective way.
Quality supervision encompasses inspections of the first article, in-process measurements, and final dimensional checks using calibrated instruments. Tools and machine settings involve a high-performance CNC program, machine tools, proper fixture deployment, and tool management to maintain tight tolerances. The process guarantees the same end result every time by regulating cutting speeds, feeds, lubrication, and thermal effects on the aluminum extrusion profile.
Surface finishing methods such as anodizing, powder coating, and polishing improve appearance and increase surface durability after machining. Anodizing not only makes the metal more corrosion-resistant but also enhances its wear resistance, while powder coatings not only protect the base metal but also provide it color. Proper cleaning, deburring, and pretreatment of machined aluminum surfaces are necessary to achieve strong adhesion and durable finishes, particularly for outdoor or marine applications.
Extrusion profile design, the selection of the alloy, and the complexity of machining operations affect the costs of the parts significantly along with the time taken for setting up CNC machines and the batch size. The use of standard cross-sectional profiles and optimized tooling cuts down on the cycle time. Proper setup for fixtures and work-holding, the use of high-speed machining centers, and the elimination of secondary operations such as excessive deburring contributes to reducing unit costs while at the same time maintaining very high precision and manufacturability.
