How aluminium extrusions are reshaping global manufacturing industries

Over the century, industries have woken up to the benefits of the lightweight and versatile metal product. Aluminium extrusion is light, strong, and non-corrosive; blends with other metals without compromising on strength and durability. The malleability of aluminium allows for more options in design and it can be recycled endlessly.

 Aluminium extrusion functionality

 There is an almost limitless variety of forms an aluminium extrusion can take. Extrusion’s design flexibility allows a great deal of functionality to be designed into extruded components, improving performance, saving secondary operations and speeding subsequent assembly. Some designs will prove very challenging to extrude, while minor tweaks to an extrusion design can often yield significant benefits in extrudability, and consequently, cost.

Aluminium extrusion applications

Aluminium extrusions can be used to build/assemble gaming chairs for the gaming enthusiasts, to incorporating it in structural panels and mechanical and electronic components of automobiles, trains, boats, and even space shuttles. There is an assortment of aluminium extrusion products that are customized to the specific requirements of the customer.

Aluminium extrusion in construction

Aluminium extruded products such as aluminium stairs, aluminium railings, aluminium panels, and aluminium framing components are gradually replacing the traditional wooden, concrete, or iron fixtures.

Extruded aluminium is not just limited to exterior design and function, either. Lighting fixtures, elevator shafts and stairwells all employ many different applications. While aluminium can’t make up the basic frame skeleton of a building, it accents and aids the structure in the interior.

Aluminium extrusion in the automobile industry 

Aluminium extruded products used to be restricted to engine mounts, radiator frames, brake components, seat frames, and a few other minor applications. Through recent years, the use of aluminium extrusions has increased in the automotive industry. Below is a comparison of how various OEM’s have used aluminium extrusions:


OEM Year Application
Chevrolet 2013 Chevrolet introduced the 7th generation Corvette Stingray with a standard all-aluminium frame. This comprised of aluminium extrusions and castings, the new frame reduced weight by 45 kg (99 pounds) while providing 60% increased stiffness.


Tesla 2013 The award-winning Tesla Model S is an aluminium-intensive design, featuring extensive use of aluminium sheet along with multiple castings and extrusions yields a body-in-white weighing 25% less than a key segment competitor. Aluminium extrusions also find application in the battery box, rear suspension and side impact system.


Ford 2014 Ford launched the aluminium-intensive F150, the highest volume North American vehicle and the highest volume aluminium-intensive application. Roughly 22 kg of automotive aluminium extrusions are used in the front end and roof structure
Cadillac 2016 Cadillac introduced their aluminium-intensive CT6. The aluminium extrusions are found throughout the structure, and include multi-hollow rocker and engine cradle components. The result is a weight savings of over 90Kg vs. high-strength steels and a body in white lighter.


The NSX features a multi-material space frame with extensive use of aluminium extrusions. Extrusions are used for the front and rear frame rails, side rails, numerous cross members and frame members for the front and rear bulkheads, as well as for the Instrument Panel (IP) structure.

Automobile equipment parts made from aluminium extrusions stand out as a result of their lightness, design, forming optimization, and safety standards. With safety norms being made top priority all over the world, the extruded aluminium automotive components manufactured in modern times have a better finish and improved quality.

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