Design Decision – Advantages with

Aluminum Extrusions
There are any number of ways in
which extruded aluminum can be 1.
applied to meet design challenges
more effectively, more efficiently, or
more economically than alternative
methods of manufacture. The
following illustrations offer just a few
common examples.

1. As shown, several rolled shapes,

riveted together, can be replaced
by a single extruded profile,
resulting in higher strength while
eliminating joining costs.

2. Machining costs often can be 2.

reduced by extruding the desired
component to exact (or near net)
size and shape requirements.

3. Weight can be greatly decreased

by putting the metal only where
needed. The extrusion process
can put the metal exactly where
needed.

3.

Advantages

4 SECTION SIX Aluminum Extrusion Manual

4. Welded assemblies
frequently can be eliminated
by designing an appropriate 4.
extrusion. In this way, costs
can be reduced while both
strength and accuracy are
increased.

5. Sturdy multi-void hollow

profiles are available to
replace roll-formed
alternatives, often at
reduced set-up costs and
shortened lead times. 5.
6. Improved stiffness and
strength can be achieved
through extrusion. Here, a
detailed hollow profile
replaces a crimped tubular
section, at a reduced
manufacturing cost.

6.

Advantages

Designing with Aluminum Extrusions 5

 Circumscribing Circle Size Most common profiles are less than
18 inches in diameter, but a few
One common measurement of extruders are capable of producing
the size of an extrusion is the extrusions with a much larger
diameter of the smallest circle circumscribing circle diameter (CCD),
that will entirely enclose its cross- some as large as 32 inches.
section—its circumscribing circle.

This dimension is one factor in

the economics of an extrusion.
In general, extrusions are most
economical when they fit within a
medium-sized circumscribing
circle: that is, one with a diameter
between one and ten inches.

The example shown here would be

classified as a 3-to-4-inch circle-size
shape.

10 SECTION SIX Aluminum Extrusion Manual

 Design Decision - Practices
To develop a good extrusion design, the
following key characteristics should be
addressed:

u Specify the appropriate metal thickness

u Keep metal thickness as uniform as
possible
u Use metal dimensions for tolerances
u Design with surface finish in mind Rounded corners ease the flow
u Smooth transitions of metal.
u Use webs where possible
u Use ribs to straighten
u Round corners wherever possible, as an assymetrical profile or thin details at
avoiding sharp edges the end of a long flange); such tendencies
u Incorporate indexing marks. exert more influence on thin-walled shapes
than on those with typical metal thickness.
Specify the Most Appropriate Metal
Thicknesses Keep Metal Thickness As Uniform
As Possible
Specify metal thicknesses that are just heavy
enough to meet your structural requirements. Extrusion allows you to put extra metal where
Even in low stress areas, however, keep it is needed—in high-stress areas, for
sufficient thickness to avoid risking distortion example—and still save material by using
or damage. Some shapes tend to invite normal dimensions elsewhere in the same
distortion during the extrusion process (such piece. Adjacent-wall thickness ratios of less
than two-to-one are extruded without
difficulty, but large differences between thick
and thin areas may create dimensional
control problems during extrusion. It is best
to maintain near uniform metal thickness
throughout a shape if possible. When a
design combines thick and thin
dimensions, streamline the
transitions with a radius (a
curve, rather than a sharp
angle) at junctions where
the thickness changes
sharply.
Practices
Metal thicknesses should be
appropriate.

Designing with Aluminum Extrusions 11

 Use Metal Dimensions for
Best Tolerance

Dimensions measured across solid

metal are easier to produce to close
tolerances than those measured
across a gap or angle. So rely on A “Metal Dimension”
so-called metal dimensions as much can be extruded to
as possible when designing close- close tolerances.
fitted mating parts or other shapes
requiring closer tolerances.
Standard industry dimensional
tolerances are entirely adequate for
many applications, but special
tolerances can be specified if
necessary. An “Open Space
Dimension” is more
difficult to hold to
close tolerances.

Design with Surface Finish

in Mind

Always indicate “exposed surfaces”

on your design drawing so the
extruder can give them special This shape, with sharp
attention and protect their finish angular transitions,
during both extrusion and post- risks show-through
extrusion handling. streaks on the
opposite surface.
As a general rule, the narrower the
exposed surface, the more uniform
its finish.

Webs, flanges, and abrupt changes Modifying the shape

in metal thickness may show up as by rounding the
marks on the opposite surface of an transitions reduces
extrusion, particularly on thin the chance of
sections. The marking of exposed opposite-side
surfaces can be minimized by streaking.
thoughtful design.

12 SECTION SIX Aluminum Extrusion Manual

Smooth All Transitions in
Thickness
Smooth transitions can
Transitions should be streamlined by a be achieved through
generous radius at any thick-thin rounding corners.
junction.

Web Gives Better Dimensional

Control The hollow condition
of the part can be
Metal dimensions are more easily held avoided by making
than gap or angle dimensions. The web the component in
also allows thinner wall sections in this two pieces as shown
example. by the dotted line.

Ribs Help Straightening

Operation

Wide, thin sections can be hard to

straighten after extrusion. Ribs help to
reduce twisting, and to improve flatness. Ribs reduce twisting.

Rounded Corner Strengthens

Tongue

The die tongue is less likely to snap off Rounded corners are
when the corners of the profile are stronger corners.
rounded at the narrowest area of the
void.

Built-In Indexing Mark

Shallow extruded grooves make drilling, An extruded groove

punching, and assembly easier by could eliminate the
eliminating the need for center- need for center-
punching. An index groove can also be punching.
used to help identify pieces that are
similar in appearance, or to distinguish
an inside (rather than an outside)
surface.

Designing with Aluminum Extrusions 13

Design Decision - Assembly Assembly
Extruded shapes can incorporate
essential design features such as
screw bosses, card slots, or drill
guides. Thus, aluminum profiles
enhance the usefulness of the
part produced.

The joining of aluminum

extrusions can be accomplished
by way of nine distinct methods
that can be designed into the
profiles themselves:

1. Nesting
2. Interlocking
3. Snap-fit
4. Three-piece interlock
5. Combination
6. Slip-fit
7. Hinge joint
8. Key-lock joint
9. Screw slot

A nesting joint.
Nesting Joints

Nesting joints which include lap joints and tongue-and-

groove joints, have mating elements that are shaped to
be assembled with little or no self-locking action.

Interlocking Joints

The interlocking joint is, in effect, a modified tongue-

and-groove. But instead of being straight, the two
mating elements are curved, therefore, they cannot be
assembled or (more to the point) disassembled by
simple straight-line motion. They are assembled by a
rotating motion and will not separate without a
corresponding counter-rotation. As long as the parts
are held in their assembled position, they strongly
resist separation and misalignment in both the An Interlocking joint.
horizontal and the vertical directions.

14 SECTION SIX Aluminum Extrusion Manual

 Snap-Fit Joints

A “snap-fit” or “snap-lock” joint is one which is

self-locking and requires no additional
fasteners to hold the joint together.

The mating parts of a snap-fit joint exert a cam

action on each other, flexing until one part slips
past a raised lip on the other part. Once past
this lip, the flexed parts snap back to their
normal shape and the lip prevents them from A snap-fit joint.
separating. After it is snapped together, this
joint cannot be disassembled unintentionally.

A Three-Piece Interlocking Joint

A three-piece joint can be designed with a

blind (hidden) fastener interlocking the two
principal extrusions. Such a design presents
one side with a smooth appearance and no
visible mounting hardware.

Combination Joints A three-piece

interlocking joint.
Nesting, interlocking and snap-fit joints can be
combined in the same extruded assembly.

For example, snap-fit elements can easily be

combined with rotating elements.

Assembly In example at above, a single extruded shape is designed for

mating with identical parts that are rotated into assembly and
then snap-locked rigidly into position without auxiliary
fastening. The tight surface-to-surface contact in this design
also provides resistance to sliding between the parts.

Designing with Aluminum Extrusions 15

Slip-Fit Joints

Slip-fit joints are assembled by sliding

two extruded mating parts together in
the direction of their length. They are
generally classified either as close-
fitting, rigid dovetail joints or as loose,
freely-rotating hinge joints.

Dovetail joints are useful in many

products where a simple, strong, This dovetail joint is a
permanent connection is required. type of slip-fit joint.

Hinge Joints

The cross-section of the components

of a hinge joint have ball-and-socket
shapes that allow them to rotate
without separating. Hinge action
through 60 to 90 degrees is easy to
obtain; incorporating adequate
reinforcement, hinge joints may be
designed to rotate beyond 90
degrees. Since the hinge joint is A pair of extruded components
relatively “loose,” provisions should make up this hinge joint.
be made to prevent lateral (side-to
side) slippage.

A number of profiles could be assembled in

series for this type of hinge joint.

16 SECTION SIX Aluminum Extrusion Manual

Key-Locked Joints Keyed interlocks of this type permit rapid,
easy assembly and disassembly, making
These unusual joints have two or more them particularly adaptable to temporary
primary elements which are locked and portable installations, as well as
together only when an additional relatively permanent structures.
specialized part, the key, is slid into
position.

The joint shown here is used to connect

two or more panels. In the illustration, two
panels and their extruded joining elements
are seen edge-on from the top or bottom.
The three hook-profiled extrusions nest
together, but are not in fact joined until an
extruded pin with a special profile is
inserted into the space at the center,
locking them in place.

This unique key-locked joint

won an award in an
international extrusion
design competition
cosponsored by the
Aluminum Association and
the Aluminum Extruders
Council.

Assembly

Designing with Aluminum Extrusions 17