Design & manufacture of bespoke
aluminium extrusions and profiles
As bespoke manufacturers of aluminium profiles for use in a variety of different industries, the extrusion process is central to our work. This involves passing aluminium logs through custom prepared dies. These dies shape the metal into profiles, consistent along their length. We design and manufacture profiles to your specifications, creating new dies to shape this versatile metal for any need.
Generally the logs of aluminium are heated by furnaces to very high temperatures, often around 500 degrees Celsius. This prepares the metal for being driven through the bespoke die which has been prepared precisely to create the desired profile of aluminium. At this stage the metal is still in its cylindrical shape and is made more malleable and ready for extrusion by the extreme temperature. Whilst ‘cold extrusion’ is also an option, ‘warm extrusion’ is the more common process to bring out the maximum ductility of the material.
It is driven through the die whilst lubricant is applied to minimise friction and sticking through the machining process. An enormous amount of pressure is required in order to drive the aluminium through the extrusion machine. When the aluminium has passed through the die, driven by a ram, it goes on to be cooled.
Once the profiles have been created and cooled, they pass onto next stage of the machining process. A saw cuts the lengths of custom profiles into their required lengths. To speed up the ageing process of the metal and ensure maximum strength, they are then heated in furnaces a final time. This artificial ageing process is a slower and lower temperature one than the initial heating which the metal undergoes, and can last up to 48 hours, though more often is around 4 to 5 hours. Whilst the metal will age naturally given time (usually around 500 hours) this isn’t often a practical possibility given the need for quick turnaround between order and delivery and the amount of storage space required for natural ageing. This process increases the overall yield stress and tensile strength of the aluminium profile.
By using this process, as an aluminium extrusion supplier, we can create custom pieces to order. This process is performed with precision and expertise to ensure the finest quality service is supplied, whether we’re creating an extensive line of aluminium extrusion profiles, or whether it’s a one off piece.
The strength, durability and versatility of aluminium when used in this way means that it has a vast selection of applications. Including window frames in construction, fencing, frameworks and even toilet bolts. Aluminium is a very effective heat barrier, meaning that it is great at containing heat within a building during the winter, as well as keeping it out during the warmer months. With windows and doors being key areas of focus in temperature control (this is where a lot of heat comes and goes) the use of aluminium in this context is understandable.
Extruded aluminium is also often used in aviation, because of its combination of strength and its lightweight quality. It is a real asset of the metal that it can be shaped with such variety, with such wide applicability.
Because of our heat ageing process, we can offer fast turnaround times for our clients. We pride ourselves on the bespoke design service we offer, working with your requirements and creating a custom profile to order, rather than a one size fits all offering. From the initial plan through the manufacturing process, we work to our customers’ needs, designing, creating and finishing to the highest standard with a made to measure service. Our 30 years of experience have earned us an excellent reputation and a client base which returns to us time and again for their aluminium extrusion needs.