Manufacturing services · Chapter E · Method 30

Metal extrusion

A heated aluminium billet is pushed through a shaped steel die to make long profiles with a constant cross-section.

Ask about this method All Metal production methods

Aluminium extrusion press with dies. Representative process photo · Swoolverton · CC BY-SA 3.0 · Wikimedia Commons

Aluminium extrusion die set. Representative process photo · Swoolverton · CC BY-SA 3.0 · Wikimedia Commons

How it works

Metal extrusion, step by step.

A labelled schematic of the process (not to scale), and the four steps every job goes through.

Labelled diagram showing how metal extrusion works — Schematic · not to scale. Drawn by TCI Group.

STEP 01

Heat billet

Heat the billet to extrusion temperature.

STEP 02

Press

A ram pushes the billet through the die.

STEP 03

Stretch

Stretch to straighten and relieve stress.

STEP 04

Age & cut

Age harden, cut to length and finish.

Reference figures

What to expect.

Typical industry values to help you plan. We agree the figures for your part on the drawing.

Cross-Section±0.25 mm or ±0.006 mm/mmWhichever is greater

Wall±10 %Of specified wall

Twist≤0.5° per 300 mmTypical

FinishRa 3.2 µmAs extruded

Materials	Aluminium 6060, 6063 and 6082; copper and brass profiles by request.
Finishes	Anodised, powder coated, brushed or as extruded.
Design guidance	Keep walls balanced; avoid very thin tongues. Minimum 0.4 mm corner radius. Add machining allowance for critical features.
Best suited to	Frames, rails, heat sinks, enclosures and architectural sections.
Watch-outs	Die cost is modest but minimum order lengths apply.

Other methods in Metal production

Previous: Progressive die stamping Next: Metal injection moulding (MIM)

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Send a sketch, photo, sample or CAD file with your quantity and target date. We will recommend the most sensible route and explain the trade-offs before quoting.

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Reference figures are typical published industry values for planning, not a guarantee; final tolerances, materials and finishes are agreed in writing for each project.