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Custom Aluminum & Plastic Extrusion Service

If you're looking for low-volume custom extrusion parts, Alpha-Mold is your ideal partner. We collaborate with solid extrusion manufacturers to offer high-quality aluminum and plastic extrusion services. Whether you need small or large-sized parts, we can shape aluminum alloys and high-performance plastics to meet your precise specifications.

At Alpha-Mold, we pride ourselves on our strong CNC machining capabilities, allowing us to provide precision post-machining for your custom extrusions. This ensures high-quality results with fast lead times, all under one roof.

Plastic Extrusion Services

We work with various thermoplastic materials like nylon, polypropylene, polystyrene, and polythene. These plastics are heated and pressured into molds, transforming them into custom shapes and sections based on your design needs.

Aluminum Extrusion Services

Aluminum extrusion involves shaping aluminum by forcing it through a die with a specific opening, creating elongated parts with consistent profiles. This process delivers durable, lightweight, and corrosion-resistant components for various applications.

Choose Alpha-Mold for custom extrusion services that combine precision, efficiency, and superior quality.

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What is Aluminum Extrusion?

Aluminum extrusion is a manufacturing process where aluminum alloy is heated and forced through a die to create long, continuous shapes with a specific cross-sectional profile. These profiles can range from simple shapes like rods or tubes to more complex designs, depending on the requirements.

The extrusion process starts by heating the aluminum to make it malleable, then using a hydraulic press to push it through a custom-made die. As the aluminum exits the die, it takes on the shape of the opening, resulting in uniform, continuous lengths of the desired profile. Afterward, the extruded parts are cooled, stretched, and cut to the required lengths.

Aluminum extrusion is widely used in industries such as construction, automotive, electronics, and aerospace because of the material's lightweight, strength, and corrosion resistance. It’s commonly used to produce components like frames, beams, heat sinks, and enclosures. The process is also cost-effective and flexible, allowing for custom profiles and precision manufacturing.

The Advantages of Aluminum Extrusion

Design Flexibility

One of the key advantages of aluminum extrusion is its ability to create complex and custom shapes, including intricate profiles that would be difficult to achieve with other methods. This makes it ideal for a wide range of applications, from architectural to industrial designs.

Lightweight with High Strength

Extruded aluminum offers an excellent strength-to-weight ratio, making it both lightweight and durable. This characteristic is crucial in industries like automotive and aerospace, where reducing weight without sacrificing strength is a top priority.

Corrosion Resistance

Natural corrosion resistance is a standout feature of aluminum extrusion. The metal forms a protective oxide layer that shields it from environmental factors like moisture and air, making extruded aluminum products long-lasting, even in harsh conditions.

Cost-Effective Manufacturing

The aluminum extrusion process is highly efficient, resulting in minimal material waste and lower production costs. The ability to produce high-volume, precision-engineered profiles makes it a cost-effective solution for large-scale manufacturing.

Sustainability and Recyclability

Aluminum extrusion is not only sustainable but also environmentally friendly. Aluminum is 100% recyclable, and using recycled material requires significantly less energy than producing new aluminum, making it a sustainable choice for companies aiming to reduce their environmental impact.

The Application of Aluminum Extrusion

Automotive Industry

Aluminum extrusions are widely used in the automotive industry to manufacture lightweight yet strong components such as frames, chassis, engine parts, and roof rails. The high strength-to-weight ratio of extruded aluminum helps improve fuel efficiency and vehicle performance.

Construction and Architecture

In the construction and architectural sectors, aluminum extrusion is used to create window frames, curtain walls, doors, facades, and structural supports. Its durability, corrosion resistance, and versatility make it ideal for both interior and exterior applications in modern building designs.

Electronics and Electrical Systems

Extruded aluminum is crucial in the electronics industry for manufacturing heat sinks that dissipate heat from electronic devices like computers, LED lights, and power supplies. Its excellent thermal and electrical conductivity make it perfect for managing heat and optimizing electrical systems.

Aerospace Industry

The aerospace industry relies on aluminum extrusions for lightweight components like aircraft frames, panels, and engine parts. The strength and corrosion resistance of extruded aluminum help improve fuel efficiency and ensure safety in high-stress environments.

Furniture and Consumer Goods

Aluminum extrusion is used in creating furniture frames, display fixtures, and modular systems. The T-slot profiles commonly found in extruded aluminum allow for easy assembly and reconfiguration, making it a preferred choice for manufacturers of modular furniture and consumer products.

Common Finishes for Aluminum Extrusion parts

We offer a range of finishing options to enhance the appearance, durability, and performance of your aluminum extruded parts. Here are some of the most popular finishes we provide:

CNC Machining

Our CNC machining processes can be used as a finishing technique to add intricate details such as etching and engraving to your aluminum extrusions. We also perform cutting, threading, face milling, and slotting to ensure precise and functional parts.

Powder Coating

Powder coating involves applying a dry, colored powder to the extruded part, which is then melted and hardened to create a durable finish. This technique provides excellent chemical resistance, color consistency, and texture options that may not be achievable through wet painting. It’s a great alternative to anodizing.

Painting

Painting is a versatile finishing method that allows for a variety of colors and textures, including matte, gloss, or textured finishes. This process is ideal for altering the surface appearance and improving the aesthetic of aluminum extrusions.

Polishing

Polishing creates a smooth, high-quality surface finish. Before polishing, the aluminum part is sanded to remove imperfections and ensure the final surface is sleek and reflective. Polishing is ideal for applications requiring a mirror-like finish.

Anodizing

Anodizing enhances the natural oxide layer on aluminum, improving its corrosion resistance and surface hardness. This process is commonly used for decorative finishes, heat dissipation, and as a primer for painting. Anodized surfaces can also be color-matched, offering both functional and aesthetic benefits.

Custom Finishes

We offer a wide variety of custom finishes tailored to the material and intended use of your part. If you don’t see the finish you need, Click here to visit our finishing page for more detailed information on available options, or contact us for bespoke finishing services

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