Custom Aluminium Extrusion Die Design: A Buyer's Checklist

Start with the function of the custom aluminium profile

Show the component in its assembly as well as in cross-section. Identify the interfaces that matter: a mating extrusion, cover, seal, fastener or mounting surface. Tell the manufacturer which features are fixed by that interface and which can be reviewed during development.

For example, a channel intended to retain a specific nut needs more context than an outside-width dimension. Include the nut reference, the relevant interface dimensions and the approved assembly requirements. This lets the design discussion focus on a working connection while keeping the full profile geometry visible.

Review wall thickness, radii and transitions

The Aluminum Extruders Council's design guidance recommends attention to wall consistency, smooth transitions and rounded corners when reviewing extrusion efficiency. It also explains that complex shapes need a discussion with the extruder. A general design guide is a starting point for that review, rather than a universal manufacturing limit.

Mark any wall or radius that is controlled by the application and identify where a change could be considered. Ask the manufacturer to explain proposed changes against the function. Keep structural or assembly requirements with the responsible designer while the extrusion team reviews the proposed manufacturing route.

Identify functional features and visible faces

A profile can include ribs, grooves, chambers and other features for a particular assembly. Label their purpose on the design brief. This helps distinguish a critical interface from a decorative feature, and it gives a proposed geometry change a clear reason to be accepted or rejected.

Also mark visible faces and the intended finish. A custom architectural section may need a different appearance discussion from a concealed equipment member. Put those requirements on the drawing or an associated controlled specification so tooling, trial inspection and finish review refer to the same brief.

Specify tolerances for the finished component

Identify the dimensions that control assembly and agree the relevant tolerances and inspection method. Include cut length, straightness or other geometric requirements where they are specified for the order. Ask whether a critical feature will be assessed as extruded or after a further operation.

For a component with holes, threads or machined faces, connect the extrusion drawing to the finished-part drawing. State the locating surfaces and processing sequence required by the design. This allows the quotation and sample plan to address the component you will assemble, including any agreed secondary operations.

Compare an existing profile with a new extrusion die

Ask whether an existing section can meet the approved requirement before deciding on new tooling. Compare the complete proposed route: geometry, further processing, material, finish, sample approval and commercial quantities. A familiar catalogue section and a custom profile should be assessed against the same finished-part need.

For a new die, agree the tooling scope, ownership or use terms, trial responsibilities and any revisions needed after the first review. Request the stages relevant to your drawing. A tooling price and a general lead-time statement leave the approval work unclear unless the sample and release process is also defined.

Approve the trial against a controlled drawing

Set the trial acceptance plan before production release. Identify the dimensional checks, material records, assembly evaluation and finish reference required for the component. Name the person who can approve the result and record any change to the drawing or specification made during the review.

Omalco's drawing-led custom extrusion route can start with the section, application and expected quantity. Add your material condition, finish, further operations and delivery location to that enquiry. For repeat orders, reference the accepted revision and sample so the earlier development work remains usable.

• Full cross-section, drawing revision, units and the intended application.
• Mating parts, functional features, visible faces and specified tolerances.
• Material condition, finish and finished-component processing requirements.
• Tooling terms, trial checks, approval owner and repeat-order references.

Frequently asked questions