Capalex Aluminium Extrusions
Aluminium Extrusions
Capalex Aluminium Extrusions

Design Considerations for Aluminium Extruded Profiles

As Aluminium extrusions and machined profiles are becoming more popular to use as a material, there are many design considerations.


Wall Thickness

Large variations in wall thickness on an extruded section can often casue issues and needs to be managed carefully in the design. An initial consultation will go a long way to minimise potential later issues and provide a more robust product.


Simple Shapes

Although a wide variety of aluminium shapes can be extruded, some factors need to be taken into consideration.
Simple aluminium shapes are the most cost effective, as the dies will be relatively uncomplicated - affecting cost and turnaround times.
The more complicated the shape the more expensive the die costs may be.

Sharp or Rounded Corners

Generally all corners are rounded, have a radii. Sharp corners should be avoided or minimised.


Dimensional Tolerances

All extrusions need to take tolerances into account at the design stage. This may help improved fit of things like mating parts for instance.

Capalex conform to standard tolerances on design & form supplied to BSEN 755.  Standard material composition supplied to BSEN 573.  There are other standards in existance, these can be discussed during the initial consultation and design stage.



Some specific design criteria that may need to be considered are as follows.

Screw Ports

Clip Fits

Hinge Joints

Solid or Hollow Profiles

Screw Threads


Precision measurements being made on aluminium extrusions. Can also be used on components after machining from the extruded section
preparation of a custom made hollow die in our die shop