Alt Text: Blue background, top centered panoramic image of the entire extrusion manufacturing line. Under the image is text reading “Designing Standard and Custom Aluminum Extrusion Profiles - Questions about the process, design and profiles? Read Star’s quick guide to get the answers you need.” Under the text is the Star Extruded Shapes logo.

This is a quick guide to designing standard and custom aluminum extrusion profiles. Star will answer your questions and walk you through the process.  

Why We Are Your Premiere Aluminum Extrusion Provider

You have a vision? Star has a solution. At Star Extruded Shapes, Inc., we have the knowledge, experience, and tools to produce all types of aluminum extrusion profiles with turnkey capabilities. Including finishing and assembling abilities for your extruded aluminum components. So, let’s get into the basics.

What is Extruded Aluminum?

Aluminum extrusion is the method of forcing aluminum through a shaped opening in a die or mold, producing a desired configuration of the final product. For example, think of children’s modeling clay. It comes with a shape tool kit, featuring different molds and profiles. First select a specific profile then push the clay through the uniquely shaped hole and out comes the predicted shape – hence, extruded aluminum.

What is an Aluminum Extrusion Profile?

Aluminum profiles are products created from aluminum alloys that are transformed into shaped objects through the extrusion process. Therefore it’s unique combination of physical characteristics makes it ideal for this process.

Whether you come to Star with a full fabrication print or just an idea, we work with you to achieve your fabrication and design requirements. Utilizing computer-aided design (CAD) and computer-aided manufacturing (CAM) programs helps to create and execute your fabrication needs.

Aluminum extrusions are used in a variety of products, including parts for aerospace, agricultural, automotive, construction, consumer, defense, windows, doors, and more. That’s why Star is a full-service manufacturer of standard and custom aluminum extrusions with capabilities encompassing a wide range of aluminum profiles and shape configurations.

Here at Star, we take your idea and turn it into reality. Our experienced team of engineers will help you with any specific configurations and determines the best approach for tooling and machining to bring your custom aluminum extrusion profile into reality.

Star provides a variety of standard aluminum shapes and profiles readily available for production. With an extensive standard aluminum extrusion catalog that includes aluminum angles, bar profiles, channel profiles, H profiles, J profiles, rectangular tubes, rod, round tubes, T profiles, and Z profiles, you are sure to find the right fit.

Two “T” aluminum extrusion profile shapes.

Aluminum T Bar Profiles

We offer an array of extruded aluminum T profiles, including sharp or rounded corners, along with stem and flange round corners.

90-degree angle “Z” shaped aluminum extrusion profile

Aluminum Z Bar Profiles

This profile is used in general engineering and commercial and military aircraft development, an aluminum Z profile features the highest strength and durability in physical composition while also being pliable with welding, forming, and machining.

6 different stacked channel “U” shaped aluminum extrusion profiles

Extruded Aluminum Channel Profiles

Best leveraged for automotive, construction, and filtration, aluminum channel profiles can be customized with either sharp or round corners.

“H” shaped aluminum extrusion profile.

Aluminum H Channel Profiles

H Channels are available in various sizes and treatments, they also work best for wall panel usage or structural support.

“J” shaped aluminum extrusion profile

Aluminum J Channel Profiles

We provide a variety of sizes and treatments for our extruded aluminum J profiles.

Rectangle shaped aluminum extrusion profile with a hollow center.

Rectangular Aluminum Tubing

Providing a selection of bends, angles, and grooves to match your project specifications.

Circle shaped aluminum extrusion profile with a hollow center.

Round Aluminum Tubing

Round aluminum tubing is utilized for structural support in a variety of applications, including architecture, automotive, defense, and more. Also available in a range of finishes.

Solid cylinder-shaped aluminum extrusion profile.

Aluminum Rod Profiles

Rod profiles offer superior flexibility to be cut, drilled, threaded, painted, and anodized.

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More About Star Extruded Shapes

Star Extruded Shapes is a premiere one-stop shop for all your aluminum extrusion needs and supporting services. We serve a wide range of markets with our extensive offerings. Known for delivering high-quality, competitively priced products, and exceptional customer service, we prioritize timely delivery to ensure complete customer satisfaction. Our steadfast commitment to innovation and excellence in design and manufacturing distinguishes us as a top choice for aluminum extrusion projects.

Star is here to help you from start to finish.

Do you still have questions or want to know more about the aluminum extrusion design process? Contact our team today to discuss what will be the best profile, process and get a quote.

Find out even more about the aluminum extrusion processes HERE.