Aluminum Extrusion Machining – Cut, Drill & Finish
Standard and custom aluminum extrusions cut to length and CNC-machined to assembly-ready precision: 6063-T5 and 6061-T6 profiles with drilled, tapped and milled features to ±0.05mm, anodized or powder coated. Custom profile dies from 2 weeks, MOQ flexible for frames, heat sinks and enclosures.
Free Consultation±0.5mm
Cut Length Tolerance
±0.05mm
Machined Feature Tolerance
2-3 Weeks
Custom Die Lead Time
Up to 6m
Profile Length
Materials
| Grade | Properties | Typical Applications |
|---|---|---|
| AL6063-T5 / T6 | The extrusion workhorse: excellent surface quality, outstanding anodizing response, good corrosion resistance. Tensile 240-290 MPa. Machinability is good with sharp positive-rake tooling; the most economical choice for profiles and frames. | Industrial frames, enclosures, architectural trim, LED profiles, display hardware, solar panel frames |
| AL6061-T6 | Higher strength than 6063 (310 MPa tensile) with equally good machinability. The choice when the profile carries structural load or must be threaded and machined aggressively. | Automation frames, structural rails, machine guards, load-bearing assemblies, heat sinks with machined ports |
| AL6005 / AL6082-T6 | Structural grades between 6063 and 7075: 6082 reaches 310 MPa with good weldability and corrosion resistance, widely used in European profile engineering. | Load-bearing structures, ladder and platform components, truck bodies, pressure-bearing frames |
| AL6463 / Decorative Grades | Optimized for anodizing and appearance: smooth, uniform surface with consistent color acceptance after anodizing. Frequently used for consumer-visible trim. | Furniture frames, retail display profiles, appliance trim, decorative hardware |
| AL7075-T6 (Machined Sections) | Highest-strength extrusion-grade aluminum (572 MPa). More difficult to extrude and anodize, machined with controlled parameters – used only where strength justifies the cost. | Aerospace frames, motorsport structures, high-load tooling rails |
| Other Alloys & Steel Inserts | AL5052 for marine exposure; 6060 for lightweight non-structural trim. We also machine brass and stainless threaded inserts into profiles where aluminum threads would wear. | Marine hardware, coastal structures, high-cycle assembly joints |
Process Parameters
| Parameter | Standard Range |
|---|---|
| Maximum Profile Cross-Section | Ø250mm circumscribed circle; up to 400mm wide flat profiles |
| Standard Extrusion Length | 6m (custom lengths cut to order, ±0.5mm) |
| Minimum Wall Thickness (Extruded) | 1.0mm standard; 0.8mm achievable on simple shapes |
| Extrusion Tolerance (Profile Shape) | Per GB/T 14846 / EN 755-9 and EN 12020-2 general tolerance classes |
| Machined Feature Tolerance | ±0.05mm standard; ±0.02mm on critical features |
| Cutting Angle Accuracy | ±0.5° standard; ±0.2° with fixture-stop machining |
| Hole Position Accuracy | ±0.1mm with drilling jigs; ±0.05mm with CNC positioning |
| Straightness After Machining | ≤0.5mm per meter; ≤1.0mm per meter on long slender profiles |
| Surface Roughness (Machined Ends) | Ra 3.2μm as-cut; Ra ≤1.6μm with finishing pass |
| Custom Die Lead Time | 2-3 weeks for new profiles; 1 week for modifications to existing dies |
Surface Finishes
Mill Finish (As-Extruded)
Natural extruded surface, Ra 1.6-6.3μm depending on die quality. The default for internal frames and parts that will be assembled and hidden. Economical and immediately available from stock profiles.
Anodizing (Natural / Silver)
Clear anodizing, 8-15μm, protects the extruded surface and gives a uniform satin-silver appearance. The standard finish for frames and enclosures that will be visible in service.
Anodizing (Black / Color)
Dyed anodizing in black, bronze, champagne, gold or custom colors, 8-15μm. Popular for consumer-visible trim, retail displays and branded equipment. Color consistency is best on 6063 and 6463 grades.
Powder Coating
Electrostatic polyester powder coat, 60-100μm, in any RAL color. Excellent weather and chip resistance for outdoor structures, architectural profiles and playground or fitness equipment.
Electrophoresis (E-Coat)
Aqueous electrophoretic coating giving a smooth, uniform, corrosion-resistant film with excellent appearance – common on decorative European-style profiles and appliance frames.
Brushed & Sandblasted
Mechanical surface treatment before anodizing to hide extrusions streaks and produce a consistent directional or matte texture. Frequently specified for consumer electronics enclosures and display hardware.
Design for Manufacturing (DFM)
- Design profiles with uniform wall thickness – extrusion dies flow aluminum evenly only when walls are balanced; thick-to-thin transitions create distortion and die problems
- Keep the tongue ratio (gap area to overall area) moderate: deep narrow slots and channels are hard to extrude and often impossible to anodize uniformly
- Avoid completely closed cavities – every hollow shape needs a die-supported bridge, and the resulting seam line is visible after anodizing
- Add machining allowances (0.5-1mm per machined face) where features will be CNC-cut after extrusion: extrusion tolerances are looser than machining tolerances
- Specify datums on the drawing for drilled and tapped features – tell us which extruded surface or slot is the reference, or the holes will be positioned from a different edge than you expect
- Prefer standard die shapes where possible: modifying an existing die costs a fraction of a new one and cuts weeks off lead time
- Group all machined features (holes, taps, pockets) on the same face of the profile where the design allows – one setup on our CNC keeps positions consistent
- Use standard alloy 6063 for appearance parts and 6061 for structural parts; mixing grades on one assembly is fine but each profile should match its function
- Add chamfers or small radii at cut ends – square-cut ends leave sharp burrs that complicate assembly and handling
- For multi-profile assemblies, send the assembly drawing – we can machine matching hole patterns across different profiles so they align on assembly
Tooling & Capacity
| Type | Lead Time | Suitable For |
|---|---|---|
| Stock Profile Cutting (Saw + Fixture) | 2-5 days from stock; 7-10 days if extrusion must be produced | Frame sections cut to length with square or angled ends, no machining. Fastest route when profiles are standard shapes |
| Cut + Drill / Tap (Jig Machining) | 5-10 days depending on feature count | Frame systems needing end taps, bolt holes, cable slots and bracket positions – the most common extrusion machining work |
| Full CNC Machining (3-axis) | 7-15 days depending on complexity | Profiles with pockets, flats, precision bores, counterbores and end-face milling; multi-face features machined in dedicated setups |
| Custom Extrusion Die | 2-3 weeks die + 1 week trial extrusion | New profile shapes with no standard equivalent; die cost is amortized across volume so unit price stays close to stock profiles |
Quality Assurance
- Incoming extrusion inspection: profile shape, wall thickness, straightness and surface quality verified per batch before cutting
- Cut length verification with calibrated tape or gauge every piece on length-critical orders; sample check on long runs
- Cut angle verification against drawing on mitered and angled ends
- Hole position verification with plug gauges and CMM on the first piece of each batch (FAI)
- Straightness and flatness check on machined faces – long profiles are measured on a surface plate
- Thread inspection with go/no-go gauges on all tapped features
- Anodizing thickness and adhesion spot-check; color match verified against approved reference sample under standardized lighting
- Assembly fit-check service: we assemble machined profiles together (or against your hardware) and report alignment before shipping
- Batch traceability: extrusion lot, anodizing batch and machining records retained; material documentation available with shipment
Applications
- Automation and robotics: machine frames, linear rail bases, cable carrier supports, safety guards
- Electronics enclosures: extruded housings for power supplies, LED drivers, controllers and test equipment
- Thermal management: heat sink profiles with machined mounting faces, CNC-finned blocks, liquid-cooling plates
- LED and lighting: extrusion profiles for light bars, strip-light housings, diffusers and trims
- Solar and new energy: panel frames, mounting rails, battery tray components
- Retail and display: extruded frames for signage, exhibition stands, product displays
- Architectural and furniture: trim profiles, door and window components, furniture frames, towel and shelf hardware
- Transportation: interior trim, cargo rails, partition frames for trucks and specialty vehicles
Why Choose FHY Precision
Extrusion plus machining under one roof: profiles are extruded, cut, drilled, tapped and anodized in one supply chain – no finger-pointing between suppliers when a hole pattern is off
Custom dies in 2-3 weeks: new profile shapes are designed for extrusion (balanced walls, sane tongue ratios) before the die is cut, so trial extrusion succeeds the first time
Machining precision where it matters: extrusion tolerances stay loose (and cheap) on the profile itself, while machined features reach ±0.05mm with fixture or CNC positioning
Assembly-ready supply: we can machine complete frame kits – every profile cut, drilled and tapped to assemble without further work, packed per assembly with drawings
Anodizing and powder coating integrated: finishing happens in controlled batches with color reference samples approved before the full run
Material breadth: 6063, 6061, 6005, 6082 and decorative grades, plus brass and stainless inserts machined into profiles where threads must last
Fit-check before shipping: multi-profile assemblies are test-assembled in our shop, so alignment problems are caught here, not on your line
Flexible quantities: from a handful of cut lengths for a prototype frame to volume production of standard profiles
FAQ
1. What is the difference between extruding and machining aluminum?
Extrusion pushes heated aluminum through a shaped die to create a constant cross-section profile – it is how frames, rails and heat sinks get their shape, and it is cheap per kilogram but limited to constant cross-sections. Machining cuts features (holes, pockets, threads) into material. Most real products use both: extrusions for the long sections, machining for the ends, holes and interfaces. We do both in-house.
2. Can you cut and machine standard stock profiles?
Yes – most of our extrusion work starts from standard or semi-standard profiles. Send the profile number or a sample and we will match it, cut to length, and add whatever machining your assembly needs. If a standard shape does not exist for your function, we design a custom die.
3. What tolerances should I expect on cut lengths and machined features?
Cut lengths hold ±0.5mm with fixture stops (±0.2mm with CNC positioning). The extruded profile itself follows general tolerance standards (EN 12020-2 / GB 14846) because extrusion is a hot-forming process. Machined features – holes, taps, pockets, end faces – hold ±0.05mm, or ±0.02mm on critical dimensions. We will tell you which class applies to each feature on your drawing.
4. How much does a custom extrusion die cost?
Custom dies are priced by profile complexity – simple solid shapes are the cheapest, hollow multi-cavity shapes the most. Typical lead time is 2-3 weeks for the die plus about a week for trial extrusion. The die cost amortizes across your volume, so unit pricing on custom profiles approaches stock-profile pricing once quantities are meaningful. We also look for existing dies that can be modified for a fraction of the cost.
5. What is the minimum order quantity for extrusion work?
Cut-and-machine work on stock profiles has no practical minimum – a handful of lengths is fine. Custom-die profiles need enough volume to amortize the die, typically 300-1000kg of extrusion depending on profile weight. We will give you honest guidance on which route pays off at your quantity.
6. Can you anodize machined extrusions? Will the machined areas look different?
Yes, and this is a real consideration: anodizing exposes bare aluminum at every cut end and machined face, so freshly machined areas anodize brighter than the original extruded surface. We manage this by masking, by bead-blasting machined areas to match texture, or by clear-anodizing everything for a uniform appearance. For color anodizing, we approve a reference sample with you before the full run.
7. Which aluminum alloy should I choose for my profile?
6063-T5 for appearance and general-purpose frames (best anodizing, easiest extrusion). 6061-T6 when the profile carries structural load or will be machined aggressively (higher strength). 6082-T6 for European-style structural engineering. 6463 for decorative, color-critical trim. We will recommend based on load, appearance and machining content – and mixing alloys across one assembly is acceptable.
8. Can you supply complete frame kits that assemble without further work?
That is one of our most requested services. Send the assembly drawing; we extrude or source the profiles, cut every length, drill and tap every hole and bracket position, anodize the batch, then pack per assembly with an assembly drawing and hardware list. Kits arrive ready to bolt together, with alignment verified by a test assembly in our shop.
9. What is the maximum profile size you can extrude?
Standard capacity is profiles up to 250mm circumscribed circle diameter and about 400mm wide for flat shapes, in lengths up to 6 meters. Larger profiles are sometimes possible with partner presses – tell us the cross-section and we will confirm.
10. How do you handle heat sink profiles specifically?
Heat sinks are extruded with high fin-density dies, then machined on the mounting face to guarantee flatness (machined Ra 1.6μm or better) and precise hole positions for the device it cools. Fins stay as-extruded. Where standard fin geometry does not meet your thermal target, we design a custom die – fin height, thickness and spacing are all die-defined variables.
11. Do you work from customer-supplied profiles?
Yes. If you already extrude profiles elsewhere, send them and we will cut, machine and finish to your drawing. We inspect incoming profiles for straightness and wall thickness on receipt and flag any issue before machining.
12. What lead times should I plan for?
Stock profiles, cut and machined: 5-10 business days. New custom dies: 3-4 weeks including trial extrusion, then 7-10 days for machined production. Anodizing adds 3-5 days. All dates are confirmed in writing with the quotation.
13. What is tongue ratio, and why does it matter?
Tongue ratio is the depth of a semi-hollow cavity divided by the width of its opening – how deep and narrow the slot the die steel must bridge. Above about 3:1, the die tongue can snap under extrusion pressure, taking the tool and your schedule with it. The fix is design-side: widen the opening, shallow the channel, or split the feature. We check tongue ratio on every hollow or semi-hollow profile during DFM, before steel is cut, because a broken tongue is a tool-room problem that becomes a launch-date problem.
14. How uniform do wall thicknesses need to be?
Keep adjacent wall thickness ratios below 2:1 where the design allows. Large thickness variations cause uneven metal flow, which shows up as distortion, twist, tolerance variation and surface sink marks. Where variation is unavoidable, make the transition gradual rather than abrupt. Minimum practical wall is typically 1.0-1.5mm for standard profiles depending on alloy and circumscribed diameter; very thin walls in a small profile are as challenging as thick walls in a large one, because flow control gets harder.
15. What tolerances should I expect as-extruded versus after machining?
As-extruded tolerances follow EN 755-9 or Aluminum Association standards – realistic for the process, typically ±0.15-0.3mm on cross-section dimensions depending on size and complexity, with straightness around 1.5mm per meter. Chasing ±0.05mm directly from the die multiplies tooling cost and rejection rates. The efficient split: standard extrusion tolerances for the profile shape, then CNC machining for holes, threads, sealing faces and tight mating dimensions. Extrude to shape, machine to precision.
16. Why do extrusion lines show more after anodizing?
Long, uninterrupted flat faces concentrate extrusion lines and flow marks, and anodizing etches the surface slightly – which makes those lines more visible, not less. Options: introduce ribs, radii or surface features that break up the flat area, accept minor variation with an agreed visual standard, or polish before anodizing to reduce it. For visible architectural parts we agree a cosmetic standard and reference sample before production, because 'perfectly flat and uniform' is a machining requirement, not an extrusion outcome.