When designing a new product or component, one of the most important decisions is whether to use a standard aluminium profile or invest in a custom aluminium extrusion.
Both options have advantages. The right choice depends on your project requirements, production volumes, performance expectations and long-term manufacturing objectives.
This guide explores the differences between standard and custom aluminium profiles and outlines when each option may be the most effective solution.
What are Standard Aluminium profiles?
Standard aluminium profiles are commonly available shapes that can be supplied without the need for custom tooling.
Examples include:
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Angles
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Channels
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Flat bars
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Round tubes
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Square tubes
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Rectangular hollow sections
Because the tooling already exists, standard profiles typically offer lower upfront costs and faster lead times.
What is a Custom aluminium extrusion?
A custom aluminium extrusion is designed specifically for a unique application.
A dedicated extrusion die is developed to create a profile that meets exact performance, dimensional, and manufacturing requirements.
Custom extrusions allow multiple functions to be integrated into a single profile, reducing the need for secondary operations and assembly.
When should you choose a Standard profile?
Standard profiles may be the best option when:
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Production volumes are relatively low
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Existing shapes satisfy design requirements
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Lead times are critical
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Budget constraints limit tooling investment
For many straightforward applications, standard profiles provide a practical and cost-effective solution.
When is a Custom extrusion the better choice?
Custom aluminium extrusions often deliver greater value when:
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Production volumes are higher
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Weight reduction is important
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Structural performance needs optimisation
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Product differentiation is required
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Assembly processes need simplification
While custom tooling requires an upfront investment, long-term manufacturing efficiencies can often offset those costs.
Understanding extrusion die design
The extrusion die is critical to achieving the desired profile shape and performance.
Effective die design considers:
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Material flow
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Wall thickness
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Structural requirements
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Surface finish expectations
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Manufacturing efficiency
Early involvement from extrusion specialists can help identify opportunities to improve manufacturability and reduce overall costs.
Long-term cost considerations
When comparing standard and custom profiles, it's important to look beyond initial tooling costs.
Custom profiles can often:
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Reduce assembly time
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Eliminate additional components
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Simplify fabrication
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Improve product performance
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Lower lifecycle manufacturing costs
For many manufacturers, these benefits create substantial value over time.
Examples of Custom aluminium extrusions
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Transport Applications: Lightweight structural components designed to improve efficiency and reduce weight.
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Industrial Equipment: Integrated profiles that simplify assembly and maintenance.
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Construction Systems: Custom profiles that combine structural performance with architectural requirements.
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Manufacturing Solutions: Profiles designed to incorporate wiring, fixings, seals and other functional elements.
Working with an aluminium extrusion partner
The most successful projects begin with collaboration. An experienced extrusion partner can assist with:
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Profile optimisation
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Material selection
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Die design
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Fabrication requirements
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Surface finishing options
Early engagement often results in better outcomes and improved manufacturing efficiency.
There is no one-size-fits-all answer when choosing between standard and custom aluminium profiles.
For some projects, standard profiles provide simplicity and speed. For others, custom aluminium extrusions unlock opportunities to improve performance, reduce costs and create a more efficient manufacturing process.
By understanding your project requirements and engaging extrusion experts early, you can select the solution that delivers the greatest long-term value.
Talk to Altus® Industrial Aluminium
Whether you're evaluating a standard profile or developing a custom extrusion, our team can help identify the most effective solution for your application.
Frequently Asked Questions
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What is the difference between a standard aluminium profile and a custom aluminium extrusion?
A standard profile is an existing shape that can be supplied immediately, while a custom extrusion is specifically designed for a particular application and requires dedicated tooling. -
When is a custom aluminium extrusion worth the investment?
Custom extrusions are often worthwhile when production volumes are high or when design optimisation can improve performance and reduce manufacturing costs. -
Are custom aluminium extrusions more expensive?
They typically involve an upfront tooling cost, but can reduce overall manufacturing expenses through greater efficiency and simplified assembly. -
How long does it take to develop a custom aluminium extrusion?
Timelines vary depending on profile complexity, die design requirements and production schedules. -
What industries use custom aluminium extrusions?
Custom extrusions are widely used across construction, transport, manufacturing, marine, aerospace, renewable energy and industrial sectors. -
Can custom aluminium extrusions reduce assembly costs?
Yes. Custom profiles can integrate multiple functions into a single component, reducing the number of parts and assembly processes required. -
What factors should be considered when designing an aluminium extrusion?
Considerations include structural performance, material selection, wall thickness, tolerances, finishing requirements and manufacturing methods. -
Can custom aluminium extrusions be machined and finished after extrusion?
Yes. Extrusions can be cut, machined, fabricated, anodised, powder coated and assembled depending on project requirements.
