Aluminum Extrusion
Custom aluminum extrusion, built to your drawing
We extrude custom aluminum profiles from your CAD drawing — designing the die, selecting the alloy and finishing the part so it arrives ready to assemble. No catalog, no stock profiles: every section starts from your specification.
What custom aluminum extrusion means
Extrusion pushes heated aluminum billet through a steel die to form a continuous cross-section. For custom parts, the die is designed around your profile, so the shape, wall thickness and features are yours alone.
We run both direct (forward) and indirect (backward) extrusion, manage the welding seam (for hollow sections) and control the discard so you get consistent, sound material. After extrusion we can age, straighten, CNC machine, bend, weld and finish the profile in one flow.
Result: extruded aluminum parts that go from drawing to finished component without changing hands.
Why Teyalu for extrusion
- Die designed and owned per project (NDA available)
- Alloy and temper matched to your application
- DFM review before tooling — fewer surprises
- Machining & finishing in the same flow
- English engineering support, 24h response
Extrusion design guide (DFM)
The earlier we review your drawing, the fewer revisions later. Key rules for an extrudable profile:
Wall thickness
Keep walls uniform. Minimum wall ≈ 1.0 mm for small sections; vary thickness gradually, not abruptly.
Inner fillets
Use generous corner radii (≥ 0.5 mm). Sharp internal corners accelerate die wear and cause tearing.
Fin limits
Fin height-to-thickness (fin ratio) up to ~40:1 is practical. Very thin, tall fins need skived or bonded construction.
Weld seams
Hollow profiles have seams where the ports rejoin. Place them away from critical surfaces where possible.
Tongue ratio
Avoid slender tongues between slots — high tongue ratio dies are fragile and limit tolerance.
Tolerances
Standard EN 755-9; tighter bands available with post-machining. See our tolerances guide.
Aluminum alloys we extrude
Selection drives strength, corrosion resistance, thermal conductivity and finish quality. Common choices:
| Alloy | Typical use | Strength | Corrosion | Notes |
|---|---|---|---|---|
| 6063 | Architectural & general | Medium | Very good | Best surface finish, easy anodize |
| 6061 | Structural, machined | High | Good | Weldable, versatile workhorse |
| 6082 | Structural, EU projects | High | Good | Common in Europe (EN AW-6082) |
| 7075 | High-strength | Very high | Fair | Aircraft-grade, harder to extrude |
Full comparison incl. 6061 vs 6063 in our materials guide.
Extrusion capability
| Parameter | Capability |
|---|---|
| Max profile width | 500 mm |
| Press tonnage | up to 1800 T (project-dependent) |
| Minimum wall | ≈ 1.0 mm |
| Length | up to 6 m (or cut to length) |
| Straightness | per EN 755-9 |
| Secondary | CNC, bending, welding, anodizing, powder coat |
Need a number before you commit?
- Tell us alloy, cross-section and quantity — we return a tooling estimate and lead time.
- MOQ and die cost depend on section size; share the drawing for an exact quote.
Profile families we build
Most custom aluminum parts fall into these groups — pick the closest and we'll tailor it.
Heat sink profiles
Finned sections for thermal management — our most specialized branch.
See heatsinks →Tubes & bars
Round, square and shaped tubes and bars — feedstock for bending.
Specialty profiles
Rails, slides, solar frames and other custom cross-sections.
Send your profile drawing for a quote
CAD, STEP or PDF — we'll return alloy, DFM notes and pricing. Or get a free DFM review first.