Custom aluminum extrusions

Custom Aluminum Extrusions

Bonnell Aluminum is a manufacturer of custom aluminum extrusions. Extrusion is defined as the process of shaping material, such as aluminum, by forcing it to flow through a shaped opening in a die. Extruded material emerges as an elongated piece with the same profile as the die opening.

To aid in understanding the aluminum extrusion process, think about a Play-Doh® Fun Factory and how it works. Think of the Fun Factory as the extrusion press, the handle as the ram, the shape bar as the die, and the Play-Doh® as the aluminum billet. The first step is to choose the desired shape and color. Think of the shape as the die and the color as the temper and alloy needed. Next, the Play-Doh® is inserted into the holding chamber and pressure is applied to the handle, which forces the Play-Doh® through the shape. In an extrusion press, pressure is applied to the aluminum billet by the ram where the dummy block is attached to the end of the ram stem. When Play-Doh® begins to emerge, it has effectively been "extruded". The same principles apply to extrusions from aluminum billets but considerably more detailed and sophisticated technologies are involved.

For more information, please visit our Extrusion Process page under Resources.

Benefits of Custom Aluminum Extrusions

  • Highly suitable to receive a wide range of finishes - paint, anodizing
  • Can easily be fabricated - cutting, drilling, punching, machining, bending, and other conventional fabrication methods
  • Can be joined to other aluminum products or to different materials by welding, soldering, brazing, bolts, rivets, clips, adhesives, clinching, slide-on, snap-together, interlocking joints
  • Can be designed for easy and reduced assembly
  • Can be designed and produced as complex and integral shapes
  • Can be designed and produced to close tolerances
  • Aluminum extrusions can be recycled and re-melted back into aluminum

In addition to custom extrusions, we have a number of profiles available for mill order quantity production. Please see our Standard and Architectural Shapes catalogs for more details.