Precision Custom
Aluminum Extrusion
Services
From custom dies to finished parts, we deliver complex aluminum profiles for prototypes and mass production runs.
Complex Profiles| Fast Tooling | ISO 9001 Certified | Full Finishing Services
What is Aluminum Extrusion?
Shaping Aluminum with Precision Force
Aluminum extrusion is a process used to transform aluminum alloy into objects with a definitive cross-sectional profile for a wide range of uses. The process involves heating a solid billet of aluminum and forcing it through a custom-shaped die, similar to squeezing toothpaste from a tube. The result is a continuous piece of aluminum that perfectly matches the die’s profile, ready for cutting and finishing.
Our Core Extrusion
Capabilities
Custom Extrusion Dies
We design and manufacture high-precision extrusion dies in-house, ensuring optimal material flow, tight tolerances, and long tool life.
Solid, Hollow & Semi-Hollow Profiles
From simple solid bars and angles to complex, multi-void hollow tubes and custom shapes, our capabilities cover all profile types.
Precision Cutting & Deburring
Extruded profiles are cut to your specified lengths with high precision, followed by deburring to ensure clean, safe-to-handle edges.
Secondary CNC Machining
We provide comprehensive CNC machining services to add holes, threads, pockets, and other precise features to your extruded parts.
Assembly & Kitting
Simplify your supply chain. We offer assembly services, kitting, and custom packaging to deliver a complete, ready-to-use product.
Prototyping & Production Runs
Whether you need a single prototype to validate your design or full-scale production runs of thousands of parts, we can meet your volume needs.
Why Choose RAPMAF
Manufacturing for Extrusion
Expert DFM Feedback
Our engineers provide free Design for Manufacturability (DFM) analysis to help you optimize profile design, reduce weight, and lower tooling costs.
Rapid In-House Tooling
With our in-house die manufacturing capabilities, we can produce and trial new extrusion tooling in a fraction of the typical industry time.
Consistent, Certified Quality
We verify all incoming aluminum alloys and maintain strict process controls to ensure every part meets ISO standards and your exact specifications.
End-to-End Solution
From die creation to extrusion, secondary machining, finishing, and assembly, we are your single-source partner, simplifying your logistics.
Scalable Production
Our flexible production lines can handle everything from low-volume prototype runs to high-volume blanket orders with scheduled releases.
Alloy & Temper Expertise
We guide you in selecting the perfect aluminum alloy and temper (e.g., 6061-T6 vs. 6063-T5) to match your application’s strength, finish, and cost requirements.
Technical Specifications
| Feature | Specification |
|---|---|
|
Max. Profile Circle Size |
Up to 450 mm (18 inches) |
|
Min. Wall Thickness |
0.8 mm (0.031 inches) |
|
Standard Tolerances |
ISO 2768 (Medium/Fine), specific profile tolerances on request |
|
Max. Part Length |
Up to 12 meters (40 feet) before cutting |
|
Typical Tooling Lead Time |
2-4 weeks |
|
Available Alloys |
6000 Series, 7000 Series, and more upon request |
Our Extrusion
Workflow
Step 1
Die Design & Manufacturing
We finalize your profile design, then machine, and heat-treat a high-strength H13 steel die, which is the heart of the extrusion process.
Step 2
Billet Heating & Extrusion
A solid aluminum alloy billet is heated to a precise temperature (around 500°C) and then forced by a hydraulic press through the newly created die.
Step 3
Cooling, Stretching & Cutting
The emerging profile is carefully cooled, then stretched by a “puller” to ensure straightness and relieve internal stresses, and finally cut to manageable lengths.
Step 4
Finishing, Aging & Inspection
Profiles may undergo artificial aging (heat treatment) to reach their final temper (e.g., T5 or T6), followed by surface finishing and a final quality inspection.
A Universe of Materials at Your Fingertips
6061 Alloy
Desripsion
The most versatile alloy, offering excellent strength, weldability, and corrosion resistance. Ideal for structural components, machine parts, and electronics.
6063 Alloy
Desripsion
Known as the “architectural alloy,” it provides a superior surface finish and good corrosion resistance. Perfect for window frames, enclosures, and decorative trim.
7075 Alloy
Desripsion
One of the highest-strength aluminum alloys available, comparable to many steels. Used in high-stress applications like aerospace frames and high-performance sporting goods.
Other Alloys
Desripsion
We can also source and extrude other alloys from the 1000, 2000, 5000, and 7000 series. Contact us to discuss your specific material needs.
If your project requires a specific resin not listed here, our engineering team can source and process it to meet your exact specifications.
Surface Finishing Options
As-Extruded (Mill Finish)
The natural, raw finish of the aluminum as it comes from the die.
Anodizing (Type II)
Creates a hard, corrosion-resistant, and decorative ceramic layer. Available in clear, black, and a range of colors.
Powder Coating
A durable, uniform, and protective paint finish available in a vast spectrum of colors, gloss levels, and textures.
Brushing & Polishing
Mechanical finishing processes to create a decorative linear (brushed) or reflective (polished) surface.
Sandblasting (Bead Blasting)
Creates a uniform, non-reflective matte texture, ideal for hiding minor surface imperfections.
Chromate Conversion Coating
A chemical treatment that enhances corrosion resistance and provides an excellent primer for subsequent painting.
Industries We Serve
We assemble complex robotic arms,end-effectors, and control boxes,integrating motors,sensors, and wiring
We build diagnostic equipment and lab instruments in a controlled environment,adhering to strict quality and documentation standards.
We provide final assembly for high-end audio equipment, smart home devices,and other consumer products ready for market.
We assemble ruggedized enclosures，mil-spec connectors,and mission-critical hardware with full traceability and documentation.
Showcase of Our Extruded Parts
Explore a selection of custom profiles we have manufactured, demonstrating our versatility in design, function, and finish.
Quality Controlled from Die to Delivery
- Alloy & Die Verification
We use a spectrometer to verify the chemical composition of every aluminum billet and perform a thorough inspection of the extrusion die before production.
- In-Process Profile Control
During the extrusion run, we take regular samples to check critical dimensions using laser scanners and digital calipers, ensuring consistency from start to finish.
- Final Inspection & Certification
Every finished part undergoes a final check for dimensions, finish, and straightness. We provide full material certifications and inspection reports upon request.
Related Articles &
Insights
Aluminum Extrusion: Alloys, Tolerances, and Cost Reduction
I have seen thousands of CAD files for aluminum extrusions land on my desk. 50% of them are brilliant. The other 50%? They treat aluminum
Inquiry & FAQs
We’ve answered some of the most common questions our customers ask about our high-precision laser cutting services.
We guarantee that all the files and pictures you upload will be kept confidential and no customer personal information will be disclosed.
The primary factors are profile complexity (solid vs. hollow), the size of the profile (circle size), and the number of cavities in the die. Hollow profiles require more complex, multi-part dies and are therefore more expensive.
Our standard lead time for designing and manufacturing a new extrusion die is typically between 2 to 4 weeks. After the die is made, we will produce first-article samples for your approval.
We are flexible and handle both prototype and production volumes. While there’s no strict MOQ, the per-part cost is significantly lower for larger production runs due to the setup and tooling costs.
We offer comprehensive Design for Manufacturability (DFM) support. Our engineers can review your concept and provide expert advice to improve its functionality and reduce manufacturing costs.
The “T” number refers to the temper, or the heat treatment process the aluminum undergoes after extrusion. A T6 temper (solution heat-treated and artificially aged) provides higher strength than a T5 temper (cooled from an elevated temperature and artificially aged).
We adhere to industry standards for straightness. The stretching process after extrusion is key to ensuring parts are straight, but perfect straightness is not possible. We can work to tighter tolerances if your application requires it.
Yes, we can design profiles with integrated “screw ports” or “screw bosses” that allow self-tapping screws to be used. For machine threads, we would add those as a secondary CNC machining operation.
The circle size is the diameter of the smallest circle that the entire cross-section of your profile can fit inside. This measurement determines which extrusion press is needed to make your part.
The one-time tooling charge covers the cost of manufacturing the die, which becomes your property. We will maintain and store it for your exclusive use on all future orders.
This depends on the alloy and overall profile shape, but we can typically achieve wall thicknesses down to 0.8 mm (0.031"). Thinner walls are more challenging and may affect tolerances.
Anodizing creates a hard, durable surface that is integral to the aluminum itself, so it won’t chip or peel. It provides excellent corrosion and scratch resistance while maintaining a premium metallic look.
We can match any RAL color code or a physical sample you provide. Powder coating offers a nearly limitless range of color and texture possibilities.
These are made using a more complex “bridge” or “porthole” die. The die splits the aluminum flow into separate streams and then welds them back together in a weld chamber before they exit the die, forming the hollow sections.
A 2D file (DXF or DWG) showing the cross-section is essential. A 3D file (STEP or IGS) is also very helpful, especially if secondary machining is required. Please also specify the alloy, length, quantity, and required finish.
Ready to Start Your Project?
Get a free quote and design for manufacturability analysis,
