This document provides an overview of a webinar on designing aluminum extrusions to meet product challenges. The webinar discusses: - The advantages of aluminum and the extrusion process for producing complex shapes with close tolerances. - Key design variables including alloy selection, shapes, fabrication considerations. - Case examples of how extrusions have been used. - Additional resources will also be provided. The presentation aims to provide both conceptual and practical understanding of using extrusions creatively for product design.

1. Beyond Basics: Designing
Aluminum Extrusion to Meet
Product Challenges

2. q This webinar will be available afterwards at
www.designworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #DWwebinar
Before We Start

3. Moderator Presenters
Paul Heney
Design World
Mark Telander
Alexandria Industries
Joe Jackman
ALMAG Aluminum

4. Beyond bars, T’s, and angles: Designing
extrusions to meet product challenges

5. Presented by:
Presenting Sponsor
Beyond bars, T’s, and angles: Designing
extrusions to meet product challenges
Mark Telander
Inside Sales Representative
Alexandria Industries
Joe Jackman
Vice President,
Sales and Marketing,
ALMAG Aluminum
www.priesenterprises.com

6. Introduction
3
The Shape is the Idea!
Almost any shape can be produced using
aluminum extrusion …

7. Introduction
4
The right shape, utilizing the right alloy, can then
be enhanced and perfected through additional
fabrication and finishing to yield an effective
product solution …

8. Introduction
… whether for functional or decorative
applications
5

9. Today’s Agenda
6
This presentation provides both a conceptual
and a practical understanding of how to
creatively address product challenges with
aluminum extrusions
• Advantages of Aluminum and
Aluminum Extrusion
- The Extrusion Process
• Key Design Variables
- Alloys
- Shapes
- Fabrication
• Case Examples
• Additional Resources

10. Introduction
7
Aluminum: a material with outstanding
physical characteristics
Aluminum Extrusion: often the most
functional, cost effective and quickest
path between function and form
– Incredibly versatile, capable of converting
ideas to reality quickly and inexpensively
– A near-net shape process for complex forms,
with close tolerances
Together, the metal and the process
optimize component and product
designs!

11. 8
Advantages of Aluminum
• Lightweight
• Strong
• High Strength-to-Weight Ratio
• Resilient
• Corrosion-Resistant
• Heat Conductive
• Reflective
• Electrically Conductive
• Non-Magnetic
• Non-Sparking
• Non-Combustible
• Cold Strength
• Fully Recyclable
Advantages of Extrusion
• Tailored performance – put metal where it is
needed
• Suitable for complex, integral shapes,
produced to close tolerances
• Attractive, wide range of finishes
• Virtually seamless
• Easy to fabricate
• Joinable by various methods
• Suitable for easy-assembly designs
• Produced with uniform quality
• Cost Effective
• Short production lead times
Why Aluminum Extrusions?

12. Strong
Appropriately alloyed and tempered, aluminum can
be stronger than some steels, with ultimate tensile
strengths as high as 80,000 psi to 90,000 psi or
more.
Advantages of Aluminum
9
High Strength-to-Weight Ratio
The standard aluminum frame for the 2014 Corvette
C7 is over 90 pounds lighter, yet 60% stiffer than the
previous steel frame

13. Corrosion-Resistant
Excellent corrosion resistance in a wide variety of
environments and contact with a myriad of substances. It
develops its own inert aluminum oxide film, which is
self-protective, blocking further oxidation.
Advantages of Aluminum
10
Cold Strength
• Advantages are not impaired by cold. Aluminum gains
strength and ductility as temperatures are reduced,
making it a preferred metal for cryogenic (low-
temperature) applications.
• Steel and plastics get brittle when the temperature
drops… aluminum gets stronger and tougher!
Photo: ©Action Graphics, Inc.

14. Electrically Conductive
Volume for volume, aluminum carries electricity
about 62% as well as copper. On a weight basis,
aluminum can be twice as conductive as copper,
and aluminum is often the most economical choice.
Advantages of Aluminum
11
0
20
40
60
80
100
Heat Conductive
Conducts – and dissipates - heat better than any
other common metal on both a weight and cost
basis.

15. Advantages of Aluminum
12
Sustainable & Fully Recyclable
• Can be recycled over and over without degradation of
its innate properties
• Recycling requires only 8% of the energy necessary to
produce virgin aluminum
• Extrusions can contain as much as 80%, recycled content.
Actual feedstock in 2010 contained 53% recycled content.
47%
5%
19%
29%
prime process scrap
post-ind. Scrap post-consumer
Source: Aluminum Association Life Cycle Assessment of Semi-Finished Aluminum Products in North America, Dec. 2013

16. 13
Feedstock: heated aluminum
alloy “billet”
Source: Rio Tinto Alcan
Advantages of Aluminum Extrusion
Steel die and supporting tooling
Desired final “profile” or shape
The Extrusion Process

17. 14
The Extrusion Process – Handling Equipment
Advantages of Aluminum Extrusion

18. 15
The Extrusion Process - how are
HOLLOW Shapes Extruded?
The PlayDoh flows through the opening between the
part of the die that forms the outside diameter and
the inside “mandrel” supported by two horizontal
supports.
The PlayDoh SEPARATES into two tube
halves and “welds” back together due to the
pressure needed to make it flow through the
annular opening into a tube shape.
Advantages of Aluminum Extrusion

19. Advantages of Aluminum Extrusion
16
Produced to Close Tolerances
• The ability to hold tight tolerances over the full
extruded lengths are routine and the ability of
aluminum extruders to meet even more critical
dimensions is keeping pace with advances in
technology.
Suitable for Complex, Integral Shapes
• Shapes can combine functions that would
otherwise require the production and joining of
several different parts, reducing part counts
and costs.
Welds
Screw bosses
Local thickening

20. Advantages of Aluminum Extrusion
17
Suitable for a Wide Range of Finishes
Aluminum accepts a great variety of finishes, colors
and textures (anodize, alodine, wet or powder paint,
applique, etc.)
Easy to Fabricate
• Designing with aluminum extrusions can eliminate
much fabrication and assembly steps
•.Parts can be easily cut, machined, finished, bent,
welded, fabricated and assembled.

21. Advantages of Aluminum Extrusion
18
Joinable by Various Methods
Aluminum extrusions can be joined to other
aluminum products or to different materials by all
major methods, including adhesive bonding, welding,
soldering, brazing, bolts, rivets, clips, clinching and
slide-on, snap-together or interlocking joints.
Hinge detail “Christmas tree” for joining
with wood or plastic
Screw boss on leg
Groove to accept
printed circuit cards
Groove for screw
or rivet
Groove for rubber
moulding
Drill groove
Slot for location of nut
or bolthead
Screw boss
Fluted surface for
appearance
Groove to accept
printed circuit cards
Dovetail assembly
Snap fit spring
assembly
“Heat sink”
cooling fin
Patterned surface for
appearance
Suitable for easy-to-assemble designs
Aluminum extrusions with integral connection
points have been widely used for elaborate
framing, such as the scaffolding for the Statue
of Liberty renovation and the recent repair of
the Washington Monument

22. Process Typical Part Tooling
Cost ($)
Aluminum Extrusion $500 to $5000
Stampings $5000 and up
Injection Molding $25,000 and up
Die Castings $25,000 and up
Roll Forming $30,000 and up
Advantages of Aluminum Extrusion
19
Cost-effective
• The diversity of shapes permitted by the extrusion process
cuts down or eliminates many machining and joining
operations.
• Tooling costs are modest in comparison with other
processes.
Time-effective
• Extrusion’s modest tool costs, with short lead times
facilitate the use of custom shapes to create a
signature design solution with differentiation and
enhanced function.
0
4
8
12
16
20
Typical
Tooling
Lead
Time
(weeks)

23. Choices of Alloy, Geometry (or shape), Tolerances
and Fabrication offer design flexibility …
• To tailor component performance
• To inexpensively incorporate functional details that simplify assemble,
reduce part counts, and enhance utility
…but, there are some limitations
• Circle Size (the circumscribing circle that the profile could fit through)
• Weight/Ft (Too heavy? Too light?)
• Shape Constraints
– High tongue ratios
– Somewhat balanced wall thicknesses
– Other
Key Design Variables
20

24. Availability of various profile circle size / area / weight
combinations
21
Circumscribed Circle Size in inches Corresponding Profile
weight (lbs/ft)
Cross Section Area in sq
inches
<1 1 to 7 8 to 10 11 to 14 >14
Min Max
<.050 L L x x x - 0.06
.050 to .100 G G L x x 0.06 0.12
.100 to 1.0 W W L x x 0.12 1.18
1.0 to 2.5 x W W L x 1.18 2.94
2.5 to 10 x W W G L 2.94 11.76
>10 x x W G L 11.76 -
x Not available
L Limited Availability
G Generally Available
W Widely Available
Key Design Variables: Practical Considerations
Practical Considerations: Aluminum extrusions offer outstanding design
flexibility … but there are some limitations

25.
Alloy
Major
Alloying
Elements
and
Alloy
Characteris=cs
1000
Series
Minimum
99%
Aluminum
High
corrosion
resistance.
Excellent
finishability.
Easily
joined
by
all
methods.
Low
strength,
poor
machinability.
Excellent
workability.
High
electrical
conducDvity.
2000
Series
Copper
High
strength.
RelaDvely
low
corrosion
resistance.
Excellent
machinability.
Heat
treatable.
3000
Series
Manganese
Low
to
medium
strength.
Good
corrosion
resistance.
Poor
machinability.
Good
workability.
4000
Series
Silicon
Not
available
as
extruded
products
5000
Series
Magnesium
Low
to
moderate
strength.
Excellent
marine
corrosion
resistance.
Very
good
weldability.
6000
Series
Magnesium
&
Silicon
Most
popular
extrusion
alloy
class.
Good
strength.
Good
corrosion
resistance.
Good
machinability.
Good
weldability.
Good
formability.
Heat
treatable.
7000
Series
Zinc
Very
high
strength.
Poor
corrosion
resistance.
Good
machinability.
Heat
treatable.
Typical
Extrusion
Tempers
Descrip=on
F
Extruded
and
air
cooled
O
Fully
annealed
H112
Strain-­‐hardened;
used
for
nonheat-­‐
treatable
alloys
T1
Cooled
from
an
elevated
temperature/
naturally
aged
T4
SoluDon
heat-­‐treated
and
naturally
aged
T5
Cooled
from
an
elevated
temperature/
arDficially
aged
T6
SoluDon
heat-­‐treated
and
arDficially
aged
Key Design Variables: Alloys
22
Aluminum extrusions can be produced in different alloys and processed to
different tempers to achieve desired mechanical properties.
Broadest
applicability

26. Strength is one key consideration …
6XXX alloy series
23
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
% Si
% Mg
6082
60636060
6005A
6061
60636060
6082
60636060
6061
6005A
6061
6063
6061
6082
6063
6061
6005A
6082
6063
6061
6060
6005A
6082
6063
6061
Increasing
strength
Key Design Variables: Alloys
Trim
components
Heat
sinks
Electronics
housings
Window/Façade
systems
Auto
Intrusion
Beams
Bumper
Beams
Auto
Chassis/Structural
Auto
Chassis/Structural
Solar
racking
systems
Typical
Applica=ons

27. … as is Extrudability and Conversion CostStrength**(ksi)
Extrudability index
0 50 100 150
Yield
Tensile
3003
6060/63*
6082*7020
7075
Al 99.5
6005A*
0
90
80
70
60
50
10
40
30
20
Key Design Variables: Alloys
24
*
T6,
except
6005A
@
T61
**typical
properDes
Mild
steel
Mild
steel
Source:
Rio
Tinto
Alcan

28. Yield
Strength
(min)
Surface Quality Bending Machining
(based on
chips, finish)
Joining Extrudability/
Processing/
Cost
6060/63 25 ksi Excellent finish &
corrosion
resistance
Good in T6,
VG in T1/T4
C B 100 - Superior
extrudability,
easy quench
6005A 38 ksi Superior
corrosion
resistance
Good in T6,
VG in T1/T4
C : continuous
chip, good
finish
C 95 - Superior
extrudability &
quench vs.
6061/6082
6061 38 ksi Good corrosion
resistance
Manageable in
T6511, VG in
T1/T4
C B 80 - Good
extrudability,
quench
demanding
6082 38 ksi Good corrosion
resistance
Manageable in
T6511
C B 80 – Good
extrudability,
very quench
demanding
7005 44 ksi Zn precludes
good anodize
Stress corrosion
Acceptable in
T53
B : curled
chip, good-
exc. finish
D 50 - ½ speed;
quench, special
ageing
25
Source:
Rio
Tinto
Alcan
Key Design Variables: Alloys

29. 26
(Launched 2009)
Key Design Variables: Alloys
There is often more than one “right” answer

30. Lotus used profile geometry to offset a lower strength alloy
Key Design Variables: Geometry/Shapes
27

31. Shape Classifications (per Aluminum Association)
28
Solids
Semi-hollow
Hollows
Class I Class II
Class I
(Balanced
round int. > 1”)
Class II
(< 5”, > 0.11”)
Class III
Key Design Variables: Geometry/Shapes

32. Good Design Practices
29
• Balance walls
• Avoid/minimize hollows
• Generous tapers
Uniformity
This! This!Not
this!
Not
this!
Smooth Transitions
This!Not
this!
This!Not
this!
Symmetry
This!Not
this!
• Practice symmetry/minimize asymmetrical detail
• Use grooves, webs, and ribs
• Minimize perimeter/cross-section ratio
Enhance visual surfaces
This!Not
this!
Key Design Variables: Geometry/Shapes

33. Extrusion Design Hint
Where possible, reduce deep narrow “tongues”
by re-designing the profile
30
Not this!This!
Key Design Variables: Geometry/Shapes
x
y
Tongue
raDo:
y:x

34. Extrusion Design Hint
Where possible, consider re-designing the profile
with a secondary “bend to gap” step
31
Where possible, consider re-designing the profile
with a removable tab
Key Design Variables: Geometry/Shapes

35. Extrusion Design Hint
Screw slots are often simple to incorporate in the
profile
32
Screw slots can often eliminate the need for a more
expensive hollow die (which also extrudes more
slowly, further increasing cost)
Self tapping screw Thread cutting screw
Not this!
This!
Key Design Variables: Geometry/Shapes

36. Extrusion Design Hint
Where possible, re-design the profile to reduce cost
(for example, a single void hollow die with smoothed
transitions vs. a multiple void hollow die)
33
This! Not this! This! Not this!
Or, in this case, 10% less cost, lighter, and
less likely to have die breakage.
Key Design Variables: Geometry/Shapes

37. Extrusion Design Hint
Complex hollow dies can be simplified by splitting
single profile into multiple profiles
34
1
2
Key Design Variables: Geometry/Shapes

38. SOLID
HOLLOW
1
2
3
4
5
7
6
35
Key Design Variables: Geometry/Shapes
But … sometimes it makes sense to “break the rules”
For example, sometimes a “complex hollow die” will yield
a superior solution

39. Tolerances
36
Tolerance tables, are available in Aluminum Standards
& Data published by The Aluminum Association.
Source: The Aluminum Association
Key Design Variables: Tolerances
Tighter than standard tolerances will
often be required applications, and
can be achieved by many extruders.

40. Solids
-­‐
Defini=on
The key – which are the critical dimensions?
• These?
Wall
Thickness
Base
of
Gap
Dimensions
Key Design Variables: Tolerances
37

41. Hollow/Gap
Defini=on
… or these
• Hollow/Gap Dimensions - Column 4-9
Hollow
Dimension
Gap
Dimension
Key Design Variables: Tolerances
38

42. Fabrication & Assembly
Extrusions can be machined, formed and assembled with a wide variety of familiar technologies. Yet some
processes – particularly bending and welding – benefit from prior extrusion fabrication experience
Key Design Variables: Fabrication
39

43. Key Design Variables: Fabrication
40
Fabrication
• Sawing
• Punching/piercing/drilling
• Machining
• Bending
• Welding
• Milling
• Tumbling

44. • Capable of complex bending to create unique shapes
• Multiple bending technologies: Stretch bending, CNC bending, chain bending
• Can be bent in both T4 and T5 conditions
Key Design Variables: Fabrication
Bending
41

45. Joining
The
rapid
increase
in
automoDve
aluminum
content
–
and
in
mulD-­‐material
soluDons
–
has
led
to
a
dynamic
evoluDon
in
material
joining
technology.
In
response,
a
comprehensive
Aluminum
Joining
Manual,
has
recently
been
developed.
Key Design Variables- Fabrication
The manual addresses:
• Adhesive Bonding
• Beam Welding
• Brazing
• Mechanical Joining
• Resistance Welding
• Fusion
• Combined Joining
• Joining Dissimilar Materials
To access, go to: www.aec.org/library/joining_manual.cfm
42

46. Case Examples
Often, we end up breaking (or at least bending) the “rules” to meet particular product
challenges, striving to meet
multiple objectives.
Yet Aluminum is often costlier* than
alternate materials per pound, e.g.:
Assessment
q Weight
reducDon
q Packaging
efficiency
q Cost
reducDon
q Build
process/
Manufacturability
q Serviceability
q Quality
Realistic economic comparisons should consider:
• Aluminum’s lower density (1/3 that of steel) and offsets from:
• Weight reduction, including that of secondary elements
• Reduced processing & assembly costs from “designed-in” functionality
• Maintenance savings
• End-of-life costs/credits
*e.g.
June
2014;
Source:
ycharts.com;
Worldsteelprices.com
• Global Carbon Steel Price : $714/MT
• Aluminum (LME): $1,838/MT
43

47. Steel Beam & Channel vs. Custom Aluminum Profile
Case Examples
Source:
Werner
Extrusion
SoluDons
44

48. Case Example: Medical
45
Accuray TomoTherapy
System for radiation oncology
• Issue – 64 mechanical “leaves”, coupled to a
pneumatic actuator, open and close to deliver
the prescribed radiation dosage. Occasional
breakage of the machined steel couplings
caused machine shut down.
• Objectives
- redesign the couplings for improved system
up-time
- reduce part cost and manufacturing
complexity. Existing steel couplings were
machined using EDM, requiring multiple
manufacturing steps and yielding a relatively
high cost

49. Case Example: Medical
46
• Approach
- Replace EDM steel coupling with an
aluminum extrusion, 6063 alloy, machined
and hard coat anodized
- Tweak part design for improved strength and
durability
- Laser etch identification on each part for
traceability
• Results
- No failures through 10 million cycle test
regimen
- “snap fit” assembly cut labor by 30 to 60
minutes per assembly; eliminated a tool
used for assembly
- Component manufacturing cost cut by
nearly 90%; production time cut by 75%
Coupling
as
extruded
Aber
fabricaDon
~1.5”
Assessment
q Weight
reducDon
q Packaging
efficiency
q Cost
reducDon
q Build
process/
Manufacturability
q Serviceability
q Quality
Credits:
Alexandria
Industries

50. Case Example: Building & Construction
Edith Green-Wendell Wyatt Federal Bldg
Portland, OR
Renovate this 35 year old, 520,000 sq. ft.
federal office building to achieve dramatic
reductions in energy use and water
consumption.
47

51. Photos:
Nic
Lehoux
Architect:
Cutler
Anderson
Façade:
Benson
Industries
Case Example: Building & Construction
Results: 55-60% reduction in energy use
vs. pre-retrofit
• “Reedlike” aluminum extrusions shade direct
sunlight on the West façade
• Vegetation being grown on the “reeds” for
additional shading
• Roof mount PV – provides 15% of energy need
• Double glazed windows, “smart” lighting
48
Assessment
q Weight
reducDon
q Packaging
efficiency
q Cost
reducDon
q Build
process/
Manufacturability
q Serviceability
q Quality

52. Case Example: Automotive
Lincoln MKZ Panoramic Retractable
Roof
• 10,000 per year
• Existing design in steel, 28 parts,
stamping intensive, requiring high
investment
49
Objectives:
• Cost neutral
• 25% weight reduction
• Part count reduction for reduced
labor cost

53. Approach & Results
•
6 pieces only – 2 extrusions + 4 small
aluminum stampings
• 20% weight savings
• Cost neutral with investment reduction
for volume
• 22 piece part reduction; reduced labor
cost
Case Example: Automotive
50
Assessment
q Weight
reducDon
q Packaging
efficiency
q Cost
reducDon
q Build
process/
Manufacturability
q Serviceability
q Quality

54. Case Example: Lighting
51
Center
Mount
LED
Ligh=ng
Fixture
• Issue
-­‐-­‐
Develop
a
heat
sink
for
a
new,
array-­‐style
center
mount
LED
light
fixture
for
Medical/ExaminaDon
applicaDons.
This
applicaDon
requires
dimming
from
10%
to
100%,
a
3700
lumen
output,
60,000
hour
life
and
electromagneDc
compaDbility
• Objec+ves
-­‐
reduce
mass
-­‐
preserve,
or
improve
heat
dissipaDon
effecDveness
-­‐
source
in
North
America
for
supply
chain
efficiency
Original
heat
sink

55. Case example: Lighting
52
• Approach
-­‐
Replace
solid
center
hub
with
hollow
secDon
with
uniform
wall
center
web
to
ensure
structural
performance
-­‐
Replace
solid
secDons
to
be
drilled
for
screw
akachment
with
integral
screw
bosses
-­‐
UDlize
6360
alloy
for
thermal
conducDvity,
and
to
facilitate
high
tongue
raDos
and
Dght
tolerances
• Results
-­‐
47%
weight
reduc/on
-­‐
4%
increase
in
surface
area,
for
improved
heat
dissipa/on
-­‐
elimina/on
of
secondary
drilling
opera/ons,
reducing
total
cost
and
speeding
manufacturing
1.4”
0.4”
Credits:
Almag
Aluminum
Original
part
Original
heat
sink
Redesign
Assessment
q Weight
reducDon
q Packaging
efficiency
q Cost
reducDon
q Build
process/
Manufacturability
q Serviceability
q Quality

56. Case example: Medical
53
Hercules
Pa=ent
Posi=oning
System™
• Issue
When
caregivers
have
to
reposiDon
a
hospital
or
nursing
home
paDent,
it
oben
causes
discomfort
to
the
paDent
…
and
possible
discomfort
or
injury
to
the
caregivers.
There
is
also
a
loss
of
dignity
for
the
paDent
and
a
drain
on
mulDple
caregivers’
Dme.
• Objec+ves
Develop
a
system
that
could
be
used
with
exis/ng
hospital
beds
that
would
allow
a
single
caregiver
to
reposiDon
a
paDent
in
10
seconds!
With
the
push
of
a
bukon

57. Case example: Medical
54
• Approach
-­‐
Develop
a
compact
drive
assembly
–
the
Hercules
PaDent
ReposiDoning
System™
-­‐-­‐
that
can
be
added
to
exisDng
hospital
beds;
when
acDvated,
the
drive
draws
a
special
sheet
into
its
aluminum
housing,
thereby
gently
reposiDoning
the
paDent.
-­‐
UDlize
7
custom
extrusions
to
create
the
assembly,
maintaining
a
minimal
footprint
while
handling
600
in/lbs
of
torque
• Results
-­‐
Ready
acceptance
by
hospitals
-­‐
Winner,
2014
Medical
Design
Excellence
Award
-­‐
Winner,
2014
ET
FoundaDon
Aluminum
Extrusion
Design
CompeDDon,
Professional
Category
1.4”
0.2”
Assessment
q Weight
reducDon
q Packaging
efficiency
q Cost
reducDon
q Build
process/
Manufacturability
q Serviceability
q Quality

58. Case Example: Automotive
Mercedes SL Floor Assembly
• Weight reduction was a major
objective for the most recent
redesign of the Mercedes SL,
precipitating a shift to an aluminum-
intensive (89% of the bodyshell)
design with a resulting 300 lb (140
Kg) weight reduction
55

59. Case Example: Automotive
Mercedes SL Floor Assembly
• Weight reduction was a major objective for the
most recent redesign of the Mercedes SL,
precipitating a shift to an aluminum-intensive (89%
of the bodyshell) design with a resulting 300 lb
(140 Kg) weight reduction
Results: Extruded Floor Panel
• 3 multi-void hollows, characterized by variable
wall thicknesses
• Joined by Friction Stir Welding
• Weight reduction of 6.4 lbs
• Height reduction providing additional interior
space
56
Assessment
q Weight
reducDon
q Packaging
efficiency
q Cost
reducDon
q Build
process/
Manufacturability
q Serviceability
q Quality

60. Conclusion
57
Aluminum extrusions provide a great
resource for your next product design
• They are lightweight, strong, corrosion resistant, fully
recyclable . . . a sustainable material
• They utilize tailored alloys, accommodate complex shapes,
can incorporate multiple functions and are easy to fabricate,
providing a custom design response quickly and at minimal
cost -- making aluminum extrusions the cost effective
solution
• While there are important nuances to the extrusion process,
available fabrication/finishing options, alloy selection, and
extrusion design details, there are a wealth of resources to
help you push the envelope and make superior product
design decisions
• Take advantage of the available resources and contact an
aluminum extrusion expert as early in your design process
as possible

61. For more Information and Training
Additional Resources
58
Purchase the Aluminum Design Manual 2010
edition from the Aluminum Association
(aluminum.org)
Reference other resources available from the
Aluminum Association
Aluminum Standards and Data: nominal and
specified chemical compositions of alloys; typical
mechanical and physical properties; mechanical
property limits; definitions, and dimensional
tolerances for semi-fabricated products
Utilize ASCE Aluminum Design Manual training
– go to www.asce.org/distancelearning;
click on “View a complete list of ASCE courses”,
scroll down to “Aluminum Structural Design with
the 2010 Aluminum Design Manual”

62. For more Information and Training
Additional Resources
59
• Utilize the Aluminum Extruders Council
website (aec.org) for webinars or other
key information
• Find an Extruder search
• Extrusion Applications
• Extrusion Design Resources
• Sustainability Info
• And more!
About AEC:
The Aluminum Extruders Council (AEC) is an international trade
association dedicated to advancing the effective use of aluminum
extrusion in North America. AEC is committed to bringing comprehensive
information about extrusion's characteristics, applications, environmental
benefits, design and technology to users, product designers, engineers
and the academic community. Further, AEC is focused on enhancing the
ability of its members to meet the emerging demands of the market
through sharing knowledge and best practices.
AEC Aluminum
Extrusion Manual
(www.AECmanual.org)
AEC Buyers’ Guide
(www.AECguide.org)

63. Thanks to Our Presenting Sponsors …
60
… and to all the members of AEC
To find an extruder: go to aec.org and choose “Find an Extruder”
www.priesenterprises.com
ABC Aluminium Solutions
Aerolite Extrusion Company
Akzo Nobel Coatings Inc.
Albarrie Canada Limited
Alcoa Forgings and Extrusions
Alcoa Primary Metals
Alexandria Industries
Alexin LLC
Almag Aluminum Inc.
Almex USA, Inc.
Al-Taiseer Aluminium Factory
Aluminio de Centro America
Aluminium Bahrain B.S.C,
Aluminium Products Co. Ltd.
Aluminum Shapes LLC
AMCOL Corporation
APEL Extrusions Limited
Apex Aluminum Extrusions Ltd.
Arabian Extrusions Factory
Astro Shapes Inc.
A.t.i.e. uno Informatica SrL
Azon USA Inc.
BCI Surface Technologies
Belco Industries Inc.
Bonnell Aluminum
Briteline Extrusions, Inc.
Butech Bliss
Capral Aluminium
Cardinal Aluminum Co.
CASTOOL Tooling Systems
Cometal Engineering S.p.A.
Compes International
Crown Extrusions Inc.
Crystal Finishing Systems Inc.
Custom Aluminum Products Inc.
Dajcor Aluminum Ltd.
Danieli Corporation
Dienamex
Drache USA Inc.
Dubai Aluminium Co. Ltd.
Emmebi
ETS-Exco Tooling Solutions
EXCO
Extrudex Aluminum Ltd.
Foy Inc.
Frontier Aluminum Corp.
Futura Industries Corp.
Gateway Extrusions Ltd.
General Extrusions Inc.
GIA Clecim
Glencore Ltd.
Granco Clark Inc.
Gulf Extrusions Company LLC
Houghton Metal Finishing Company
Hulamin Extrusions
Hydro Aluminum North America Inc.
ILSCO Extrusions Inc.
iNOEX LLC
International Extrusions
Jordan Aluminum Extrusions, LLC
Kennametal Extrude Hone Corp.
Keymark Aluminum Corporation
Light Metals Corporation
Magnode Corporation
Marx GmbH & Co. KG
Matalco Inc.
M-D Building Products
Metal Exchange Corporation
Metra Aluminum Inc.
MI Metals Inc.
Mid South Extrusion Die Co.
Mid-States Aluminum Corp.
Nanshan America Co.
National Aluminium Ltd.
Nizi International (U.S.) Inc.
Noranda Aluminum Inc.
Non-ferrous Extrusion
Ohio Valley Aluminum Co. LLC
OMAV S.p.A.
PanAsia Aluminium Limited
Peerless of America Inc.
PengCheng Aluminum
Penn Aluminum International Inc.
Pennex Aluminum Company
Postle Extrusion
PPG Industries Inc.
Presezzi Extrusion North America
Pries Enterprises Inc.
Profile Extrusion Co.
Republic Chemical Co., Inc.
Reliant Aluminum Products LLC
Richardson Metals
Rio Tinto Alcan
R.L. Best Company
Sapa Extrusions
Service Center Metals
Sierra Aluminum
Silver City Aluminum Corp.
SMS Meer Service Inc.
Spectra Aluminum Products Ltd.
Spectrum Metal Finishing Inc.
Superior Extrusion Inc.
Taber Extrusions LLC
Tecalex USA
Technoform
Tecnoglass S.A.
Tellkamp Systems Inc.
Thumb Tool & Engineering
Tower Extrusions, LLC
Tri City Extrusion Inc.
Tubelite Inc.
Turla S.r.L.
Ube Machinery Inc.
Valspar Corporation
Vidrieria 28 de Julio S.a.C.
Vitex Extrusion
Wagstaff Inc.
Walgren Company
WEFA Cedar Inc.
Werner Co.
Werner Extrusion Solutions, LLC
Western Extrusions Corp.
Whitehall Industries
YKK AP America Inc.
Youngstown Tool & Die Co. Inc.

64. Questions?
Paul Heney
Design World
pheney@wtwhmedia.com
Twitter: @DW_Editor
Mark Telander
Alexandria Industries
mtelander@alexandriaindustries.com
Phone: 800-568-6601
Joe Jackman
ALMAG Aluminum
Joe.jackman@almag.com
Phone: 888-457-9480
Twitter: @ALMAGAluminum
Ron Gish
Alexandria Industries
rgish@priesenterprises.com

65. Thank You
q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com

66. Proper Use of the Presented Information
62
The Aluminum Association (AA), Aluminum Extruders Council
(AEC), the authors and contributors of this overview provide
information and resources about aluminum products and
aluminum-related technology as a service to interested
parties. Such information is generally intended for users with
a technical background and may be inappropriate for use by
lay persons.
This presentation does NOT attempt to thoroughly discuss all
load types, materials, profiles, design requirements, etc.
The purpose is to provide an overview of topics/issues to
consider when utilizing aluminum extrusions for designs
Full understanding and adherence to the Aluminum Design
Manual (Aluminum Association 2010) and all documents
referenced by it is required for proper design
In all cases, users should not rely on this information without
consulting original source material and/or undertaking a
thorough scientific analysis with respect to their particular
circumstances. Information presented here does not replace
the independent judgment of the user or of the user’s
company and/or employer.
AA AND AEC EXPRESSLY DISCLAIM ANY AND ALL
GUARANTEES OR WARRANTIES WITH RESPECT TO
THE INFORMATION PROVIDED HERE. AA AND AEC
FURTHER DISCLAIM ANY LIABILITY IN CONNECTION
WITH THE USE OR MISUSE OF ANY INFORMATION
PROVIDED OR IN CONNECTION WITH THE OMISSION
OF ANY INFORMATION.
Photos, illustrations, and graphics used in this PowerPoint courtesy of: Accuray, Akzo Nobel Coatings Inc./Bill Hanusek, Gossamer Innovations, GM, Hydro Aluminum
North America Inc., Light Metal Age Magazine, MAADI Group, SAPA Extrusions, Skylne Solar, Taber Extrusions, Werner Co., Werner Extrusion Solutions, LLC