Advanced Metal Extrusion Services
Fecision specializes in customization options to meet specific project requirements. From unique cross-sectional profiles to specialized material formulations, our custom extrusion services provide flexibility for innovative product designs.
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ISO 9001:2015 Certified Processes
ISO 13485: 2016 Medical Device
IATF 16949: 2016 Automotive
AS9100 Quality Managment
Faster Lead Time for Production Needs
In-Process Inspection with CMM
Professional Metal Extrusion at Fecision
Quality Assurance in Metal Extrusion Manufacturing
Quality control in professional metal extrusion involves multiple inspection points throughout the production process.
From material verification to dimensional analysis and surface finish evaluation, comprehensive quality systems ensure parts meet or exceed industry standards.
Material certification and testing before processing
In-process monitoring of temperature, pressure, and flow rates
Dimensional verification using precision measurement equipment
Surface quality inspection for defects and finish consistency
Mechanical property testing for strength and performance validation
Different Types of Extrusion Methods
Different extrusion methods offer unique advantages for specific applications and materials.
The choice of extrusion technique impacts production efficiency, part quality, and achievable geometries.
Direct Extrusion
Indirect Extrusion
Hydrostatic Extrusion
Impact Extrusion
Lateral Extrusion
Hot Extrusion
Cold Extrusion
Warm Extrusion
Metal Extrusion Capabilities
Precision in metal extrusion requires careful attention to dimensional specifications and tolerances.
Understanding these parameters ensures parts meet functional requirements while optimizing manufacturing efficiency.
Critical Dimensional Parameters
Several key dimensions must be controlled during the extrusion process to ensure part quality and consistency:
Standard Tolerance Tables
Industry standards provide guidelines for achievable tolerances in metal extrusion. The following table outlines typical tolerance ranges for common extrusion parameters:
| Parameter | Aluminum (Standard) | Aluminum (Precision) | Steel | Copper Alloys |
| Wall Thickness | ±0.15mm | ±0.10mm | ±0.20mm | ±0.15mm |
| Linear Dimensions | ±0.30mm | ±0.20mm | ±0.40mm | ±0.30mm |
| Straightness | 1.5mm/m | 0.8mm/m | 2.0mm/m | 1.5mm/m |
| Flatness | 0.7mm/100mm | 0.4mm/100mm | 1.0mm/100mm | 0.8mm/100mm |
| Twist | 3° per meter | 1.5° per meter | 4° per meter | 3° per meter |
| Corner Radius (min) | 0.5mm | 0.3mm | 1.0mm | 0.5mm |
Basic Steps in Metal Extrusion
Metal extrusion is a forming process where material is forced through a die opening to create parts with a specific cross-sectional profile.
The process combines pressure and temperature to transform raw metal into precisely shaped components with excellent structural properties.
Preparation of feed metal (billet or ingot) to required specifications
Preparation of feed metal (billet or ingot) to required specifications
Heating the material to appropriate temperature (for hot extrusion)
Preparation of feed metal (billet or ingot) to required specifications
Loading the billet into the extrusion press container
Preparation of feed metal (billet or ingot) to required specifications
Applying force with a hydraulic or mechanical ram to push material through the die
Preparation of feed metal (billet or ingot) to required specifications
Common Materials for Metal Extrusion
The choice of material significantly impacts extrusion process parameters, achievable geometries, and final part properties.
Different metals offer unique combinations of strength, weight, corrosion resistance, and formability.
Aluminum Alloys
Key Properties:
Lightweight, corrosion resistant, good thermal conductivity, excellent formability
Common Applications:
Window frames, heat sinks, structural components, automotive parts
Extrusion Challenges:
Surface finish control, maintaining tight tolerances on complex shapes
Magnesium Alloys
Key Properties:
Ultra-lightweight, good strength-to-weight ratio, vibration damping
Common Applications:
Aerospace components, automotive weight reduction, portable electronics
Extrusion Challenges:
Fire hazard during processing, narrow temperature window
Copper Alloys
Key Properties:
Excellent electrical conductivity, good thermal conductivity, antimicrobial properties
Common Applications:
Electrical components, heat exchangers, plumbing fittings
Extrusion Challenges:
High extrusion forces, die wear, oxidation control
Titanium Alloys
Key Properties:
Exceptional strength-to-weight ratio, corrosion resistance, biocompatibility
Common Applications:
Aerospace structures, medical implants, chemical processing
Extrusion Challenges:
Extremely high forces, specialized tooling, oxidation control
Zinc Alloys
Key Properties:
Good castability, moderate strength, corrosion resistance
Common Applications:
Hardware, decorative components, electrical fittings
Extrusion Challenges:
Dimensional stability, surface quality control
Steel
Key Properties:
High strength, durability, good wear resistance, magnetic properties
Common Applications:
Structural components, automotive parts, tools
Extrusion Challenges:
Very high forces required, die wear, temperature control
Lead
Key Properties:
High density, excellent formability, radiation shielding
Common Applications:
Radiation shielding, ballast, battery components
Extrusion Challenges:
Environmental and safety concerns, low strength
Material Selection Factors
When selecting a material for metal extrusion, consider these key factors:
- Strength (tensile, yield, fatigue)
- Hardness and wear resistance
- Ductility and formability
- Impact resistance
- Weight considerations
- Corrosion resistance needs
- Operating temperature range
- Chemical exposure conditions
- UV and weather resistance
- Regulatory compliance
- Extrudability and flow characteristics
- Surface finish requirements
- Secondary operations needed
- Production volume
- Cost constraints
Popular Aluminum Extrusion
Aluminum extrusion represents approximately 75% of all metal extrusion applications due to its exceptional combination of properties, processing advantages, and versatility.
The 6000 series alloys (particularly 6063 and 6061) are most commonly used for extrusion applications.
Advantages of Aluminum Extrusion
Superior corrosion resistance without additional treatments
Highly recyclable with minimal quality loss
Excellent thermal and electrical conductivity
Ability to create complex cross-sections with tight tolerances
Good machinability for secondary operations
Cost-effective for medium to high volume production
Limitations of Aluminum Extrusion
Lower strength compared to steel extrusions
Lower hardness and wear resistance than steel
Higher thermal expansion can affect dimensional stability
Not suitable for very high-temperature applications
Potential for galvanic corrosion when in contact with certain metals
Initial tooling costs can be significant for custom profiles
| Alloy | Key Properties | Typical Applications | Extrudability |
| 6063 | Excellent surface finish, good formability, moderate strength | Architectural components, window frames, decorative trim | Excellent |
| 6061 | Good strength, corrosion resistance, and weldability | Structural components, machinery parts, transportation | Very Good |
| 6082 | Higher strength than 6061, good corrosion resistance | High-stress structural applications, bridges, cranes | Good |
| 7075 | Very high strength, good fatigue resistance | Aerospace components, high-performance applications | Fair |
| 5083 | Excellent corrosion resistance, good weldability | Marine applications, chemical processing equipment | Good |
Available Finishes for Extruded Parts
Metal extrusion parts can receive various surface treatments and finishes to enhance appearance, improve corrosion resistance, or add functional properties.
The appropriate finish depends on the application requirements and base material.
- Mill Finish – Natural finish directly from extrusion process
- Brushing – Linear, textured appearance
- Polishing – Smooth, reflective surface
- Shot Blasting/Sandblasting – Uniform matte texture
- Tumbled – Smooth edges and surfaces
- Grinding – Removes surface
- Anodizing – Electrochemical process creating protective oxide layer
- Chromate Conversion – Chemical treatment for corrosion resistance
- Etching – Controlled surface texturing
- Passivation – Removal of free iron to prevent corrosion
- Vapor Deposition (PVD, CVD) – Deposits thin films for hardness, wear resistance, and aesthetics.
- Powder Coating – Durable, decorative finish in various colors
- Electroplating – Metallic coating for appearance or function
- Painting – Liquid or spray coatings for customization and protection
- Oxidation (Black Oxide) – Improves corrosion resistance and reduces light reflection (used for steel)
Anodizing Types and Specifications
Anodizing is one of the most common finishes for aluminum extrusions, offering excellent durability and aesthetic options:
| Anodizing Type | Coating Thickness | Characteristics | Typical Applications |
| Type I (Chromic Acid) | 0.05-0.1 mil (1.3-2.5 μm) | Thin, self-healing coating with excellent corrosion resistance | Aircraft components, parts requiring tight tolerances |
| Type II (Sulfuric Acid) | 0.1-0.8 mil (2.5-20 μm) | General purpose anodizing, good corrosion and wear resistance | Consumer products, architectural components, general industrial use |
| Type III (Hard Anodizing) | 0.8-4.0 mil (20-100 μm) | Very hard, thick coating with excellent wear resistance | High-wear components, hydraulic cylinders, military applications |
| Color Anodizing | 0.3-0.8 mil (7.5-20 μm) | Decorative finish available in various colors, integrated into oxide layer | Architectural elements, consumer products, decorative components |
Metal Extrusion Application
Industries We Serve
Metal extrusion creates components for diverse industries, from everyday consumer products to specialized industrial applications. The versatility of the process allows for both standard and custom solutions across multiple sectors.
Transportation
Heat exchangers and radiators
Structural frame elements
Crash management systems
Rail car components
Aircraft structural members
Marine hardware and components
Electronics
LED lighting housings
Electronic enclosures
Cable management systems
Busbars and conductors
EMI/RFI shielding components
Power distribution equipment
Industrial Equipment
Conveyor systems
Pneumatic and hydraulic cylinders
Structural components
Robotic system elements
Workstation profiles
Material handling equipment
Construction
Curtain wall systems
Structural framing members
Railings and handrails
Solar panel mounting systems
Decorative trim and moldings
Partition systems
Case Study: Automotive Industry
The automotive sector extensively uses metal extrusion for components that require strength, lightweight properties, and complex geometries.
- Bumper Systems – Aluminum extrusions provide energy absorption while reducing vehicle weight
- Body Structure – Extruded profiles create strong yet lightweight frame components
- Heat Management – Extruded heat sinks and radiator components optimize thermal performance
- Interior Components – Seat frames, dashboard structures, and trim elements
- Battery Housings – Electric vehicle battery enclosures requiring thermal management and crash protection
Custom Metal Extrusion Solutions for Your Industry
Our engineering team specializes in developing custom extrusion solutions for specific industry applications.
From concept to production, we'll help optimize your components for performance and manufacturability.
Advantages and Disadvantages of Metal Extrusion
Understanding the strengths and limitations of metal extrusion helps determine if it's the right manufacturing process for your application.
Consider these factors when evaluating extrusion against alternative manufacturing methods.
Advantages of Metal Extrusion
- Complex Cross-Sections – Ability to create intricate, consistent profiles that would be difficult or impossible with other processes
- Excellent Surface Finish – Smooth surfaces that often require minimal post-processing
- Cost-Effective for Medium to High Volumes – Once tooling is created, per-piece costs are relatively low
- Long Continuous Lengths – Ability to produce parts in lengths limited only by handling constraints
- Tight Tolerances – Good dimensional control, particularly for metal dimensions
- Hollow Sections – Ability to create hollow profiles without secondary operations
Disadvantages of Metal Extrusion
- Initial Tooling Cost – Die design and fabrication requires upfront investment
- Cross-Section Limitations – Profile must be consistent along the entire length
- Size Constraints – Limited by press capacity and material handling considerations
- Material Limitations – Not all metals are suitable for extrusion
- Potential Defects – Surface cracking, internal cracking, and piping can occur without proper process control
- Minimum Order Quantities – May not be economical for very low volumes
- Secondary Operations – May require additional processing for features not in the extrusion direction
How to Work with Us
Submit Drawings
For a free quote, please submit a product description along with a technical drawing. We also offer reverse engineering services to assist you.
DFM & Quotation
We will provide a DFM (Design for Manufacturability) report or mold flow analysis report. Please be aware that further discussions may be needed during the process.
Mold Manufacturing
Upon your confirmation to the mold design, our team will begin making mold components, which will then be sent for inspection and assembly.
Metal Extrusion
Once the mold is complete, we will initiate the metal forming process. A T1 sample will be provided for you to check whether the product details align with your specifications. After approval we will continue massive production.
Delivery
Your custom-designed metal parts undergoes thorough inspection, will be carefully packaged, and delivered to you.
Recent Projects
Ready to Start Your Metal Extrusion Project?
Contact our team today to discuss your requirements!
Discover how our metal extrusion services can deliver the quality, precision, and value your application demands.
Metal Extrusion FAQs
While metal extrusion is more cost-effective for high-volume production, it can also be used for smal-batch production. However, the relatively high cost of die-making may make it less economically viable for extremely small quantities. But for some custom-made, high-value products, small-batch extrusion can still be a viable option.
Depends on setup time (die installation, heating, calibration) and production rate. Continuous extrusion can be 5-10 meters per minute for common aluminum extrusions, but more for complex shapes or small-batches.
Yes, in co-extrusion. But it needs careful parameter control due to different metal flow and melting points, and special die designs for bonding.
may be limited to several hundred meters.
Scrap metal is recycled. Some plants have in-house recycling, melting it to make new billets, reducing waste and raw material costs.
Related Services
Metal Stamping
Injection Molding
Die-Casting
Themoforming
Compression Molding
