Custom Aluminum Extrusion

Custom aluminum extrusion is a manufacturing process that involves shaping aluminum into specific profiles or shapes by forcing the metal through a die. The process begins with a cylindrical aluminum billet that is heated and then pushed through the extrusion mould using a hydraulic press. The extrusion mould determines the final shape and dimensions of the extruded aluminum, which can range from simple to complex aluminum profiles.Custom aluminum extrusion offers flexibility in design, allowing manufacturers to create unique shapes and sizes according to specific requirements. The process is commonly used in industries such as construction, automotive, aerospace, and electronics, where lightweight, durable, and corrosion-resistant materials are needed. The extruded aluminum profiles can be further cnc precision machined, cut, drilled, or finished to achieve the desired end product.

The grade of aluminum commonly used in extrusion aluminum heat sinks is aluminum alloys 6063-T5 and 6061-T6. These are popular choices due to their low cost,excellent thermal conductivity, corrosion resistance, and ease of extrusion.

Some of the common applications include:1. Construction and architecture: custom aluminum extrusions are widely used in the construction industry for window frames, door frames, curtain walls, roofing systems, and structural components. They offer durability, light weight, and design flexibility.2. Automotive industry:custom aluminum extrusions are used in various automotive applications such as body frames, chassis components, heat exchangers, engine parts, and interior trims. They help reduce weight, improve fuel efficiency, and enhance vehicle performance.3. Electrical and electronics:custom aluminum extrusions are utilized in the production of heat sinks, LED lighting fixtures, electrical enclosures, and power distribution components. They provide excellent heat dissipation properties and electrical conductivity.4. Transportation: custom aluminum extrusions find applications in the aerospace, marine, and rail industries. They are used for aircraft components, shipbuilding, rail carriages, and cargo containers due to their high strength-to-weight ratio and corrosion resistance.5. Industrial machinery:custom aluminum extrusions are employed in the manufacturing of conveyor systems, machine frames, robotic components, and automation equipment. They offer stability, precision, and easy customization.6. Furniture and interior design: custom aluminum extrusions are utilized in the production of furniture, shelving systems, partitions, and decorative elements. They provide a modern and sleek appearance, along with structural integrity.7. Renewable energy:custom aluminum extrusions are used in solar panel frames, wind turbine structures, and other renewable energy systems. They offer corrosion resistance and lightweight properties, facilitating easy installation and maintenance.8. Sports and leisure:custom aluminum extrusions are employed in the production of bicycles, camping equipment, sporting goods, and recreational vehicles. They contribute to lightweight and durable designs, enhancing performance and user experience.Overall, the scope of use for custom aluminum extrusion is vast and continues to expand as new applications and industries discover the benefits of this versatile material.

The process of extruding an aluminum heat sink typically involves the following steps:1. Billet preparation: The first step is to prepare the aluminum billet, which is a cylindrical-shaped piece of aluminum. The billet is usually made from aluminum alloys that have good thermal conductivity and can be easily extruded.2. Heating: The billet is heated to a specific temperature, usually around 450-500 degrees Celsius, in a furnace. This temperature is necessary to soften the aluminum and make it more malleable for the extrusion process.3. Extrusion: The heated billet is then pushed through an extrusion mould using a hydraulic or mechanical press. The extrusion mould is a specially designed tool that shapes the aluminum into the desired aluminum heat sink profile. The force applied by the press is typically several hundred tons.4. Cooling and straightening: After extrusion, the aluminum heat sink is cooled using air or water quenching to bring it to room temperature. The aluminum heat sink may also go through a straightening process to ensure it is perfectly straight and free from any deformations.5. Cutting and machining: The extruded aluminum heat sink is cut into the desired lengths using a saw or other cutting tools. It may then undergo additional machining processes such as drilling, tapping, or CNC precision machining milling to create specific features or mounting holes.6. Surface treatment: The aluminum heat sink may undergo surface treatments such as anodizing or powder coating to improve its corrosion resistance, aesthetics, and thermal performance. Anodizing involves creating a protective oxide layer on the surface of the aluminum heat sink, while powder coating involves applying a durable and protective coating using electrostatically charged powder particles.7. Quality control and inspection: Throughout the custom aluminum extrusion process, quality control measures are taken to ensure the aluminum heat sink meets the required specifications. This may involve dimensional checks, visual inspections, and testing for thermal performance.8. Packaging and shipping: Once the extruded aluminum heat sinks pass the quality control checks, they are packaged and prepared for shipping to customers or further assembly processes.Overall, the custom aluminum extrusion process allows for the efficient production of aluminum heat sinks with complex shapes and high thermal conductivity, making them ideal for dissipating heat in electronic devices and other applications.

Anodizing is an electrochemical process that creates a protective oxide layer on the surface of the aluminum heat sinks. This layer enhances the aluminum heat sink's corrosion resistance, durability, and aesthetic appearance.Anodizing can also offer better thermal performance by improving the aluminum heat sink's emissivity and increasing its surface area. The anodized layer can act as a thermal insulator, reducing the heat transfer between the aluminum heat sink and the surrounding environment. However, it is important to note that anodizing can slightly increase the thermal resistance of the aluminum heat sink, which may impact its overall cooling efficiency.Ultimately, whether or not to anodize extrusion aluminum heat sinks depends on the specific requirements and preferences of the application. If corrosion resistance, durability, and aesthetics are important, anodizing is recommended. However, if maximizing thermal performance is the primary concern, anodizing may not be necessary.

An aluminum extrusion mould for a hollow design requires two pieces of steel and the average cost is $1,200.A hollow extrusion mould takes 2~3 weeks to manufacturer.An aluminum extrusion mould for a very complex hollow design with multipe could cost from $3,000~$5,000.Welcome to send us your drawing or samples for quotation~