Aluminium Extrusion Design

Aluminium profile and section considerations as part of your product design.

Why Capalex?

If you are involved in design, research and development, prototyping or one-off projects then Capalex should be your first choice.

We are a specialist manufacturer of tight tolerance, complex aluminium extrusions that many other aluminium extruders can’t produce.

The vast majority of bigger aluminium extruders also insist on minimum orders of 250kg and typically offer a lead-time of six to eight weeks from the initial order of a new die.

Capalex have no minimum or maximum order quantity and we offer some of the best lead times in the aluminium extrusion sector.

Design Considerations

The uses of aluminium extrusions are almost limitless, and they can be adapted by shape and finish to be used in a variety of designs.

There are however some design considerations, which need to be accounted for when designing your extrusion, which can be seen in Aluminium Extrusion Design Considerations.

Capalex can offer design advice on extrusions featuring screw ports, clip features and other mating parts.

We are always willing to consider complex customer sections and, if necessary, offer advice on changes to make sections more extrudable.


Our drawing office can work from a simple rough sketch to a complex electronic file.

We have the ability to read most industry standard files types, including .dxf and .dwg files.

These are used for both die design, and machine shop CAD/CAM.

We can also work from samples if you do not have any drawings of your required extrusion.

Profile Thickness

Wall thickness can be as little as 0.5mm on flat dies and 0.7mm on hollow dies subject to design and alloy.

To see more information on the alloys Capalex supply, take a look at our datasheets.

Further information on Aluminium Alloys (external site).

How can we help?
Do you have a design query or need extrusion advice?
Contact us today to see how Capalex can help
solve your challenges.
Contact us
Capital Aluminium Extrusions Limited
Cleator Moor, Cumbria,