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Extrusion is the process of shaping aluminium by forcing it through a shape opening in a die. The resulting aluminium extrusion usually has the same profile as the die opening. The extrusion process features different steps to aid in the making of the final product.

These steps and processes include:

  • The design of the profile required is discussed and created depending on requirements and technical capability.
  • The shape and design of the die is then created.
  • A cylindrical billet of aluminium alloy is heated and transferred to a loader where a lubricant is added to keep the heated billet from adhering to the ram or die.
  • Pressure is applied using a ram which pushes the heated billet into a container which then forces it through the die opening.
  • Nitrogen gas or liquid is allowed to flow through the opening of the die to prevent oxides of aluminium from forming.
  • The newly extruded section is then passed onto a run out table. It is important to specify visible surface during design in order to protect this surface from the runners on the run out table.
  • The extruded aluminium is placed on the cooling table where it is either cooled by fans or by liquid.
  • The hardened material is then heat treated in an ageing oven and cut to size.
  • If required the aluminium etrusion can then be either painted or anodised.

For further customisation, there are other processes that can be added to the basic extrusion process. Some of the custom extruded parts that require further processing include hollow sections, piercing mandrels or pins. The colour, texture and brightness of the finish can also be adjusted after the extrusion process.


Aluminium extrusions have a wide range of applications largely because of their malleability and ductility. Some of these diverse applications include:

  • In high conductivity of electricity and heat applications like heatsinks, radiators, electronics and air conditioning
  • In applications that require low weight to high strength ratios like marine, military, stock, railway and aeronautical applications
  • In mining, architectural marine and military and other applications that require materials that are resistant to corrosion.

Leading suppliers and stockists of Aluminium Extrusions across the UK

We understand that there is more to supplying bespoke aluminium extrusion than simply having metal in stock. We have invested heavily in training staff in the correct handling and storage of extrusion, technical sales staff with the knowledge to be able to help reduce costs and dedicated account managers to ensure that we have the right amount of stock for your business needs. Coupled with our mill partnerships across the globe and our own logistics division, we are one of the leading suppliers and stockists of aluminium extrusion across the UK.

Benefits of aluminium extrusions

The process offers a wide range of benefits. With aluminium extrusions, it is possible to add extra features for fixings, interlocking systems and channels which are more convenient as opposed to having additional parts.

Paired with other processes like novel fabrication, it can be a low-cost tooling solution. Ultimately, the low cost of extrusion results into lower project costs.

The strength, durability and other properties of aluminium are not lost in the extrusion process. It is possible to extrude pure aluminium for certain applications but, in most cases, other metals are added to form alloys that build on the already impressive properties of aluminium.

Extrusion allows for aluminium to be recycled without losing its properties living up to its name as an environmentally friendly metal.

Processing Services

Cut to size

On site, we have state of the art saws capable of cutting profiles 420mm wide and lengths from 15mm to 7000mm. We can offer bespoke cuts for repeat high volume orders, as well as offering bespoke cuts for one off jobs. In total, we have 9 powerful saws that cut profiles to specific dimensions.

Punching and drilling

We offer customers with bespoke solutions to help them get the job done. We are able to drill holes or punch slots and shapes. At our new site, we only use the best equipment.


Once we have cut or fabricated the product, we can finish the job using a range of methods. De-burring, polishing, anodising, painting and screen printing.


On site, we have 3 powerful machines HAAS VFI, Matsuura V500’s and the Mecal MC 305 FAT. No job is too big or small with our specialist team.

Bespoke packaging