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Can You Really Afford Custom Aluminum Extrusion?

25-08-2020

Factors that Contribute Towards the Cost of Custom Aluminum Extrusion

If you think that custom aluminum extrusion is not affordable, you have been interacting with the wrong kind of manufacturers. You need proper planning to get custom extrusion not only on time but also within budget.

Despite steel being the common choice across industries, aluminum is becoming popular with the passing time. After all, it has a lot more to offer. It ensures corrosions resistance, durability, strength, weight, numerous finishing options and low maintenance.

What more is that with aluminum, architects and product designers are able to acquire destinations that might seem like a dream in case of steel. Aluminum contributes significantly to the sustainability efforts, after all, it is among the most recycled materials in the industry.

Aluminum Extrusion: Important Elements

Funding and feasibility are the two major factors that govern the custom aluminum extrusion. These after all a matter of the circle size along with the required weight of the shape per linear foot. Although, the combination sounds extremely complicated.

However, we can assure you that it is fairly easy to grasp. In simple terms, it is the ratio between the profile size and the thickness of the material. Sine the extrusion presses different in terms of their capability, finding the one that suits you best is the matter of looking around.

For instance, if you have a profile that has a section area ranging between 1 to 2.5 square inches and it has a diameter that is 1 to 10. Finding an aluminum extruder for this particular profile would not be a challenging task. Since it lacks complexity, most extruders would be able to do a good job.

On the contrary, if you want a profile that requires a circumscribed circle greater than 14 inches, dia and the cross section is greater than 10 square inches. This is something challenging and only experienced extruder such as the Essaii would be able to handle it with perfection.

Custom Aluminum Extrusion suppliers

Cost Factors

Die is the major contributor to the cost of the extrusion process. You would likely have to pay for 1000 of dollars for the die. However, this cost is not significant when compared to the entire architectural project.

In addition, in most cases, the lead times are usually less than a month. So, these factors would contribute the custom extruding’s affordability. For example, the revisions required, or the full-scale prototyping.

Other factors adding to the project cost include the custom-made check-fixtures along with the tools that are required for the bending machine.  In order to cut down the overall custom extrusion expense, you should consult an experienced and relevant extruder.

Design Guidelines

Even though the extruded shapes have some limitations, yet they do offer design freedom and substantial versatility. Since custom aluminum extrusion is creating a new profile form the scratch instead of purchasing off-the-shelf profile, therefore you have different options.

It is up to you to choose the dimensions, shape, structure and other aspects of the aluminum profile. Below is a basic table for guide design.

Custom Aluminum Extrusion manufacturers

Alloy Selection

When it comes to alloy selection, aluminum offers a wide variety of tempers and alloys. For instance, for the construction and building applications, manufacturers would recoomend the 6XXX series. Even though some other alloys may offer greater strength.

However, 6XXX series is excellent for electrical conductivity. It has the best combination of properties for the construction business. Alloys to consider are 6005A, 6061, 6063, and 6060.

Profile Design

Wanneer u contact opneemt met een ervaren aluminium extrusiefabrikant op maat, krijgt u leesinvoer over het profielontwerp. Het is absoluut noodzakelijk om contact op te nemen met een extruder als u nieuw bent bij extrusie. Het zal u verbazen dat kleine verschillen in het ontwerp kunnen leiden tot aanzienlijke kostenbesparingen.

Om te beginnen moet je out of the box denken. We zijn het erover eens dat I, C, L en rechthoek goed werken voor verschillende toepassingen, maar dan heb je geen aangepaste aluminium extrusie nodig. U zult de meeste van deze vormen direct uit voorraad kunnen vinden.

Vervolgens is het belangrijk om het ontwerp eenvoudig te houden om het succes van de uitvoering te garanderen en tegelijkertijd de kosten stevig vast te houden. Zie hieronder enkele effectieve tips.

  1. Gebruik zachte rondingen en hoeken.
  2. Houd de tongen zo ondiep en breed mogelijk
  3. Zorg voor een gelijkmatige dikte van de muren.
  4. Ontwerp met symmetrie in gedachten.

Als we uniek zeggen, bedoelen we niet complex. Met uniek bedoelen we een ontwerp dat het doel dient en tegelijkertijd opvallend en gedurfd is.

Oppervlaktespecificaties en toleranties

U vindt de toleranties volgens de industriestandaard eenvoudig online. Een goede en betrouwbare fabrikant van aluminium extrusie op maat zou echter een tolerantie garanderen die hoger is dan de industrienormen. Ze zijn tenslotte van plan om alleen het beste te leveren.

Een goede manier om dit te doen, is door met uw extruder te praten. Zij zouden u de vereiste informatie kunnen verstrekken, evenals hoe het verwerven van de normen uw totale kosten zou beïnvloeden. In dit stadium moet u ook de zichtbaarheid van het project bespreken, evenals de oppervlakken die bij deze specifieke gebieden horen.

Structurele overwegingen

There is no denying that creating optimal structure is more than one-time cycle. It is an iterative process that starts with the functions. It then moves through a number of forms, joining methods and geometry considerations.

For start, you should consult the aluminum design manual. It consists of the aluminum basis for the construction as per the international building standards along with aluminum structures specifications.

Custom Aluminum Extrusion offers Different Finishing

Once you extrude, the aluminum promptly creates a tenacious oxide film. The purpose of this film is to provide additional protection against corrosion. In most cases, you won’t require additional finishing.

However, if you want to enhance the physical appearance or sever service conditions, you would need additional finishing. Do bear in mind that the additional finishing would increase the cost. So, do these finishing only when they are a must.

To further know how this finishing would impact your project cost, you should talk to your extruder. They are the best source to acquire authentic and reliable information.

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