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Aluminum Extrusion: Alloys, Tolerances, and Cost Reduction

The cross-section of a custom-designed extruded aluminum beam, illustrating a constant profile shape with multiple hollow chambers.

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 like it’s plastic injection molding. Here is the brutal truth: Extrusion is not molding. It is not machining. It is the art of pushing hot, toothpaste-like metal through a steel […]

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