Plenty of design engineers who look to reduce costs often overlook extruded aluminum manufacturing for machined or stamped parts. They believe extruding aluminum is an expensive or difficult production method. That kind of opinion is often a mistake that costs much.

Luckily, today, design engineers can work closely with extruded aluminum manufacturers to enhance functionality, reduce components and remove tooling and machining to cut costs across production. There are less benefits of the implementation of aluminum extrusions in your product designs.

1. ALUMINUM EXTRUSION SAVES YOU MONEY 

Understanding the product requirements and the part’s end-use is crucial to picking the correct aluminum alloy. Aluminum provides qualities like being corrosion-proof, having high resistance to weight proportion, and electric conduction.

Aluminum Extrusion Die For Curtain Wall Profile

If a design engineer is about to utilize an aluminum extrusion for their project and encapsulate it appropriately, it can give a rigidness to the manufactured part while making it of higher value. With aluminum extrusions, rigidness and qualities such as thermal conduction and being corrosion-proof are already built-in their natural properties. 

Designers can additionally create complex forms with extruded aluminum to decrease part and unite functions to promote reduced production costs. Aluminum profiles that are almost net-shaped may include holes, slits, or screw bosses into their form, eliminating lots of secondary operations. 

Designs also work to eradicate riveting and welded assemblies, which increase overall strength and lower overall manufacturing costs. A single extrusion may cost more than a steel-shaped part. However, the total system components are repeatedly considerably lower. 

2. EXTRUDED ALUMINUM PROFILE DESIGNS AND DESIGN EVALUATION

Nowadays, designers benefit CAD, PLM, and CAM software, which they utilize to create and test their designed parts in a digital space. That way, designers examine tolerances, conditions and adjust designs once concerns, solutions, or new ideas emerge.

Aluminum extrusion allows for complex, single part profiles

After the design is confirmed within the engineering team, it’s shared with the aluminum extrusion producer. It is a vital step before manufacturing. Potenial issues caused by poor communication are minimized, and the manufacturer has a thorough understanding of what the engineering team needs.

The greatest thing to do is to get your manufacturer involved initially. Allow the manufacturers who are producing thousands of parts similar to yours to check your designs. Inform them how it’s going to be utilized because they might notice something you wouldn’t. 

3. REDUCES MACHINING TIME AND PART AS WELL AS ELIMINATING THE SECONDARY OPERATIONS

With the latest developments in alloys and cooling technologies, there is no need to choose higher-priced alloy over aluminum for numerous applications.

If necessary, you can fabricate the aluminum extrusions even further. Extrusion’s fabrication capacities involve cutting accuracy, single or double cutting, tapping, trimming, drilling, milling, perforating, and lengthy section CNC machining. 

Reduced Machining

Elegant and simple designs with minimal parts, connections, and fabrication steps result in essentially top-quality products that cost less to produce.

For instance, an aluminum extrusion part initially designed to need machining could (with a slight design change) be manufactured using punch tooling to achieve the same finish. With the aluminum extrusion methods, the extruded parts go through a cheaper fabrication method, which results in reduced overall cost and quicker machining.

A custom aluminum extruded bracket

Reduced Number Of Parts

Designers might create complex forms with extruded aluminum to reduce the number of components and unite functions which save on production and total product life cycle expenses.

For example, one extruded profile may substitute rolled figures fixed together. It results in greater resilience while eliminating connection costs and component amounts.

Secondary Operations Are Eliminated

Aluminum net-shaped profiles can contain gaps, slits, or screw bosses into their form. It eliminates a good deal of the secondary operations.

Furthermore, a designed extrusion may also eliminate welded assemblies, lowering cost while increasing parts accuracy.

Final Words

As you can see, there are many reasons to design your parts utilizing the aluminum extrusions method.

The benefits are immense, and you should employ this procedure as a part of your standard manufacturing process. It will save you a good amount of expenses and will supply you with high-quality fabricated components.

KIMSEN is proud to bring high quality extruded aluminum, machined components & assemblies which meet international standards.

Currently, KIMSEN is operating 3 modern technology aluminum extrusion lines with wattage of 920 UST, 1100 UST & 1880 UST, which are able to produce approximately 1.000 tons/month. 

Aluminum extrusion lines with wattage of 920 UST, 1100 UST & 1880 UST

For specific advice, please contact Hotline +84 93 867 6005 or email info@kimsen.vn

Source: https://ideasplusbusiness.com/aluminum-extrusion-design/