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Aluminium Extrusion Fabrication - Read More
Aluminium Fabrication - Read More
Aluminium Extrusion - Read More

Aluminium Design Rules and Tips 

To achieve a successful design of a product, some design guidelines for extrusion design will be very helpful. These guidelines will help the designer to achieve extrusions with better functionality and extrudability and by that also less production costs and better all-round economy.

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Uniform Wall Thickness

Uniform wall thickness within a section reduces the loading on the die and therefore minimises the risk of it being damaged. Big differences in wall thicknesses within a section should also be avoided in order to minimise differences in surface appearance after anodising. Uniform wall thickness is obtained by changing the shape of the extrusion and putting the material where it is most needed. 

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Rounded Shapes

As a rule all corners should be rounded. Normal radii are 0.4 to 1.0 mm. If the design requires sharper edges and corners, a radius of 0.2 mm is the smallest that can be produced. 

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Symmetry

With symmetrical extrusion designs, a balanced flow of material through the die is achieved at the same time as the load on the die is evenly distributed. The extrusion shape is more accurate at the same time as the risk for broken dies is significantly  

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Diameter of the Circumscribing Circle

Always try to reduce the circle circumscribed around the extrusion. Apart from making it easier to press the extrusion, it also helps keep die and production costs down.  

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Fewer cavities cut costs 

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A move towards a hollow extrusion gives better dimensional control

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Increased size can cut the weight and increase the rigidity 

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Heat Sinks

The design of the flanges increases the surface of the extrusion and thermal conductivity. 

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Decorative Lines

Decorative lines in an extrusion can conceal irregularities as well as protect against damage during handling and fabrication. 

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Hinge Function in Extrusions (Download pdf)

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Screw Channel Sizes in Extrusion (Download pdf)

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Screwport/Captivated Nut Slot/Weather Strip Retaining Groove/ Side Fix Screw Table of Sizes (Download pdf)


The recommended ratio between the gap depth (h) and the gap width (b) in solid extrusions

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Maximum ratio between the
gap height (h) and the gap
width (b) in solid extrusions

Gap width
b

-1
1-2
2-3
3-4
4-5
5-15
15-30
30-50
50-80
80-120
120-

Ratio
h:b

1.0
2.0
2.5
3.0
3.5
4.0
3.5
3.0
2.5
2.0
1.5