Custom Structural Aluminum Extrusion
Aluminum Extruded Frame Profiles
We make non-standard structural aluminum profiles and frames to your drawing — channels, angles, beams and bespoke sections in 6061 / 6063, finished and machined as one part. Not off-the-shelf T-slot.
Frames and structural sections, built to drawing
A structural extrusion carries load. The section shape, wall thickness and alloy decide how much — so we treat the profile as an engineering part, not a catalog item.
Most structural frames start as a standard shape — a channel, an angle, a box section — repeated along a length. Extrusion is the efficient way to get that shape in aluminum at volume: one die, consistent section, then cut, CNC and join. When an off-the-shelf section almost fits but not quite, a custom die removes the compromise: the web thickness, flange and hole pattern are set by your load case, not by what a supplier stocks.
We do not sell T-slot framing from inventory. We make the non-standard section you need and, where the application calls for it, machine the connection features — slots, clearance holes, tapped holes, end faces — in the same setup that references the extruded datum. That keeps a bolted frame square and repeatable across a run.
Section types we extrude
These are the common structural families. Any of them can be a custom cross-section.
Frame profiles
Open and closed frames for machine guards, racks, enclosures and automation cells — the backbone of a rigid assembly.
U-channel & channel profiles
U channel aluminum extrusion and open channels for rails, trims and slideways where a slot or groove is part of the function.
Angle profiles
Equal and unequal aluminum angle extrusion for brackets, edges and corner joints — stiffer than bent sheet at low volume.
Beams & posts
Box and I-section beams and posts for frames that span a gap or carry a point load. Wall and flange sized to the moment.
Heavy-duty sections
Larger, thicker-wall profiles for structural framing where stiffness per mass matters more than a thin decorative section.
Custom cross-sections
Any non-standard shape your assembly needs — we review it for extrudability before tooling.
Typical capabilities
Indicative production ranges. Final alloy, wall, tolerance and section size are confirmed against your drawing and press.
Alloys
6061 and 6063 typical for structural use; 6082 where higher strength is needed. Tempers T5 / T6 per application.
Wall thickness
Minimum wall typically ≥ 1.0 mm for sound extrusion; thicker on heavy-duty sections. Confirm against section and press.
Section size
Profile width to ~350 mm flat (250 mm circumscribed diameter) on our 3600T press; larger sections via Foshan partner heavy press on request.
Straightness & twist
Held to EN 755 general or precision class, or your tighter print. Quench and stretch reduce residual twist.
Machining
Holes, slots, faces and threads cut on CNC to ±0.01 mm typical, referenced to the extruded datum.
Finish
Anodize (Type II / III) or powder coat for corrosion and appearance; natural for internal structures.
Capability figures are conventional in-house ranges (presses 600–3600T). Confirm exact values against your drawing and press before tooling.
Design notes for structural extrusions
Small changes at the drawing stage lower cost and raise yield.
Wall uniformity. Keep wall thickness even around the section. Sudden jumps force the metal to flow unevenly and raise scrap. If a local thick wall is unavoidable, expect a longer die and more tuning.
Fillets and draft. Internal and external fillets let the alloy fill the die and release cleanly. Sharp internal corners are the usual cause of die sticking and short die life.
Connection features. If the section bolts or screws to something, tell us early. Machining the hole pattern into the extrusion beats welding a plate on later — it stays square and removes a secondary operation.
T-slot alternative. You do not need catalog T-slot to get an adjustable frame. A custom slot or groove extruded into your section gives the same adjustability with a profile shaped for your load, and no inventory of standard parts.
Where these profiles are used
Structural extrusions span most of the industries we serve.
Industrial automation
Guards, racks, slideways and cell frames built to repeatable datum.
Enclosures
Structural walls of extruded aluminum enclosures — stiffness and EMI paths in one section.
See enclosures →Conveyor & rail
Long rails and brackets for material handling, often in the specialty family.
See specialty →Questions buyers ask
Short answers before you send a drawing.
Custom extrusion vs T-slot framing — which should I use?
T-slot is a standard catalog system: you buy stock lengths and bolt them with connectors. It is fast for one-off jigs and prototypes. A custom structural extrusion is better when you make the same frame repeatedly, need a shape T-slot cannot give (a built-in groove, a specific flange, an integrated mount), or must hit a load and tolerance T-slot will not. We make the custom section and machine its features; we do not stock T-slot. For volume or a load-bearing profile, custom extrusion is usually cheaper per part and stiffer than assembled T-slot.
Aluminum vs steel for a structural frame?
Aluminum 6061 / 6082 carries less load per area than steel but roughly one-third the weight, and it resists corrosion without paint. For frames that are moved, mounted or sensitive to mass — machine guards, enclosures, automation cells — aluminum is usually the right call. For a fixed, very high-load structure where weight is irrelevant, steel can be cheaper. Send the load case; we will suggest alloy and wall.
What is the minimum wall thickness and section size?
Minimum wall is typically ≥ 1.0 mm for a sound extrusion, rising with section complexity; profile width runs to ~350 mm flat (250 mm circumscribed diameter) on our 3600T press, larger via Foshan partner network. Thinner walls and larger sections are possible but affect die life, straightness and cost — we confirm against your drawing before tooling.
What is your minimum order quantity?
MOQ is 500 kg per profile, covering die amortization. Lower-volume machined or finished parts may be possible without a new die — confirm against quantity and geometry.
Have a frame or structural section to extrude?
Send the drawing for a DFM review and quote — alloy, wall, tolerances and finish recommended before tooling.