Designing

to the Limits
of Your Imagination!
Brought to you by:

Aluminum Extruders Council

www.aec.org
ET Foundation
www.etfoundation.org

Revised July 2018

Introduction
The Shape is the Idea!

Almost any shape can be produced using

aluminum extrusion …

Images courtesy of Almag Aluminum, Inc. Hydro Aluminum, Werner Co.

Introduction
Aluminum Extrusion: Alloy + Geometry = Performance
The right shape, utilizing the right alloy, can then
be enhanced and perfected through additional
fabrication and finishing to yield an effective
product solution…allowing you to design to the
limits of your imagination!
Introduction
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 they optimize component

and product designs!
Presentation Agenda
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
• Tolerances
• Fabrication
• Finishing

• Case Examples

• Aluminum Extrusion Design

Competition

• Additional Resources

• Sample Q&As
Learning Objectives

At the end of this presentation, you should be able to:

1. Develop a basic understanding of the aluminum extrusion process and

material attributes.
2. Apply best practices in extruded part design, to optimize functionality and
production economics.
3. Understand the key variables and limitations for aluminum extrusion
design.
4. Choose additional resources key to the design and specification of
extrusion-based components.
5. Recognize the range of applications where extrusions can have
meaningful impact.
6. Demonstrate knowledge by entering a design in the Aluminum Extrusion
Design Competition.
Why Aluminum Extrusions?

Advantages of Aluminum Advantages of Extrusion

• Lightweight • Tailored performance – put metal

• Strong where it is needed
• High Strength-to-Weight Ratio
• Suitable for complex, integral shapes,
• Resilient
• Produced to close tolerances
• Corrosion-Resistant
• Attractive, wide range of finishes
• Heat Conductive
• Reflective • Virtually seamless
• Electrically Conductive • Easy to fabricate
• Non-Magnetic • Joinable by various methods
• Non-Sparking
• Suitable for easy-assembly designs
• Non-Combustible
• Produced with uniform quality
• Cold Strength
• Fully Recyclable • Cost Effective

• Short production lead times

Advantages of Aluminum
Strong High Strength-to-Weight Ratio
Appropriately alloyed and tempered, aluminum The standard aluminum frame for the 2014
can be stronger than some steels, with Corvette C7 is over 90 pounds lighter, yet 60%
ultimate tensile strengths as high as 80,000 stiffer than the prior steel frame
psi to 90,000 psi or more.
Advantages of Aluminum
Corrosion-Resistant Cold Strength
• Excellent corrosion resistance in a wide • Advantages are not impaired by cold.
variety of environments and contact with Aluminum gains strength and ductility as
a myriad of substances. temperatures are reduced, making it a
• It develops its own inert aluminum preferred metal for cryogenic (low-
oxide film, which is self-protective, temperature) applications.
blocking further oxidation. • Steel and plastics get brittle when the
temperature drops… aluminum gets
stronger and tougher!

©Action Graphics, Inc.

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

100
80
60
40
20
0
 Advantages of Aluminum
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.
prime process scrap
post-ind. Scrap post-consumer

29%
47%

19%

5%
• In 2012, North American extruders utilized ~ 1
Billion pounds of scrap

Source: Aluminum Association Life Cycle Assessment of Semi-Finished Aluminum Products in North America, Dec. 2013
Advantages of Aluminum Extrusion

The Extrusion Process

The Extrusion Process is similar to this toy Play-Doh Press.

The dough is warmed to a soft, malleable state and then forced
through a die to make the shape.
Advantages of Aluminum Extrusion
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
Aluminum Extrusion Press

Courtesy of Bonnell Aluminum

Advantages of Aluminum Extrusion

The Extrusion Process

Steel die and supporting tooling

Desired final “profile” or shape

Feedstock: heated
aluminum alloy “billet”

Source: Rio Tinto Alcan

Advantages of Aluminum Extrusion

The Extrusion Process

Container
Housing
Bolster

Die

Backer

Die
Liner Ring Pressure
Ring

Source: Rio Tinto Alcan

Advantages of Aluminum Extrusion

The Extrusion Process – Handling Equipment

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

Local thickening
Screw bosses
 Advantages of Aluminum Extrusion
Joinable by Various Methods Suitable for easy-to-assemble designs
Aluminum extrusions can be joined to other Aluminum extrusions with integral connection
aluminum products or to different materials by points have been widely used for elaborate
all major methods, including adhesive bonding, framing, such as the scaffolding for the Statue
welding, soldering, brazing, bolts, rivets, clips, of Liberty renovation and the recent repair of
clinching and slide-on, snap-together or the Washington Monument
interlocking joints.

“Christmas tree” for joining

Hinge detail
with wood or plastic

Patterned surface for Screw boss on leg

appearance
Groove to accept
printed circuit cards
“Heat sink” Groove for screw
cooling fin or rivet
Groove for rubber
Snap fit spring moulding
assembly
Drill groove
Dovetail assembly
Slot for location of nut
Groove to accept or bolthead
printed circuit cards

Screw boss
Fluted surface for
appearance
Advantages of Aluminum Extrusion
Cost-effective Time-saving
• The diversity of shapes permitted by the • Extrusion’s modest tool costs, with short
extrusion process cuts down or eliminates lead times facilitate the use of custom
many machining and joining operations. shapes to create a signature design
solution with differentiation and enhanced
• Tooling costs are modest in comparison function
with other processes

Process Typical Part Typical Tooling Lead Time

Tooling (weeks)
Cost ($)
20
Aluminum Extrusion $500 to $5000 16
Stampings $5000 and up 12
8
Injection Molding $25,000 and up 4
0
Die Castings $25,000 and up

Roll Forming $30,000 and up

Some Limitations of the Aluminum Extrusion Process
Every manufacturing process has its limitations. Some things to
consider when designing with aluminum extrusions:

• Circle Size
– The circumscribing circle diameter (CCD)
that the profile could fit through

• Weight per Foot (Wt/Ft)

– Too heavy? Too light?
– The design is greatly enhanced if the profile ccd’s are
kept under 8” and the wt/ft is 3 lbs or less

• Shape Constraints
– High tongue ratios (width of fin vs. height)
– Somewhat balanced wall thicknesses
– Other
 Some Limitations of the Aluminum Extrusion Process
Press Availability Corresponding
Circumscribed Circle Size in inches Profile weight
Chart (lbs/ft)

Cross Section Area <1 1 to 7 7 to 10 10 to 14 >14

in sq inches Min Max
<.050 L x 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
NOTE:
There are many presses available with up to 7" diameter containers
There are fewer presses available with 7" to 10" diameter containers
There are even fewer presses available with 10" to 14" diameter containers
There are very few presses available with greater than 14" diameter containers
Key Design Variables
Alloy + Geometry = Performance
The right shape, utilizing the right alloy, can
then be enhanced and perfected through
additional fabrication and finishing to yield an
effective product solution!
Key Design Variables
Tailored performance: Aluminum extrusions can be produced in different alloys
and processed to different tempers to achieve desired mechanical properties.

Alloys & Tempers

Typical
Alloy Major Alloying Elements and Alloy Characteristics Extrusion Description
Tempers
1000 Minimum 99% Aluminum
Series High corrosion resistance. Excellent finishability. Easily joined by all methods. Low F Extruded and air cooled
strength, poor machinability. Excellent workability.
High electrical conductivity. O Fully annealed

2000 Copper H112 Strain‐hardened; used for

Series High strength. Relatively low corrosion resistance. Excellent machinability. Heat nonheat‐treatable alloys
treatable.
T1 Cooled from an elevated
3000 Manganese temperature/naturally aged
Series Low to medium strength. Good corrosion resistance. Poor machinability.
Good workability. T4 Solution heat‐treated and
naturally aged
4000 Silicon Broadest
Series Not available as extruded products applicability T5 Cooled from an elevated
temperature/artificially aged
5000 Magnesium
Series Low to moderate strength. Excellent marine corrosion resistance. T6 Solution heat‐treated and
Very good weldability. artificially aged
6000 Magnesium & Silicon
Series Most popular extrusion alloy class. Good strength. Good corrosion resistance.
Good machinability. Good weldability. Good formability. Heat treatable.

7000 Zinc
Series Very high strength. Poor corrosion resistance. Good machinability. Heat treatable.
Key Design Variables
Strength is one key consideration …
6XXX alloy series
Key Design Variables: Alloys
Yield Surface Bending Machining Joining Extrudability/
Strength Quality (based on Processing/C
(min) chips, ost
finish)
6060 – 25 ksi Excellent finish Good in T6, C B 100 - Superior
T61/ & corrosion VG in T1/T4 extrudability,
6063-T6 resistance easy quench
6005A – 38 ksi Superior Good in T6, C: C 95 - Superior
T61 corrosion VG in T1/T4 continuous extrudability &
resistance chip, good quench vs.
finish 6061/6082
6061-T6 38 ksi Good Manageable C B 80 - Good
corrosion in T6511, extrudability,
resistance VG in T1/T4 quench
demanding
6082-T6 38 ksi Good Manageable C B 80 – Good
corrosion in T6511 extrudability,
resistance very quench
demanding
7005- 44 ksi Zn precludes Acceptable B : curled D 50 - ½ speed;
T53 good anodize in T53 chip, good- quench,
Stress exc. finish special ageing
corrosion

Source: Rio Tinto Alcan

Key Design Variables: Shapes
Shape Classifications (per Aluminum Association)

Solids Hollows

Semi-hollow Class I Class II

(Balanced (< 5”, > 0.11”)
round int. > 1”)

Class I Class II

Class III
Key Design Variables: Shapes
Geometry/Shapes
Good Design Practices
• Balance walls • Practice symmetry/minimize asymmetrical
• Avoid/minimize hollows detail
• Generous tapers • Use grooves, webs, and ribs
• Minimize perimeter/cross-section ratio
Uniformity Symmetry

Not This! Not This!

this! this! Not This!
this!
Smooth Transitions Enhance visual surfaces

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

This! Not this! This! Not this!

Key
KeyDesign
DesignVariables:
Variables:Geometry/Shapes
Shapes
Extrusion Design Hint
Screw slots are often simple to incorporate in Screw slots can often eliminate the need for a
the profile more expensive hollow die (which also
extrudes more slowly, further increasing cost)

Self tapping screw Thread cutting screw

This!

Not this!
Key
KeyDesign
DesignVariables:
Variables:Geometry/Shapes
Shapes
Extrusion Design Hint
Complex hollow dies can be simplified by
splitting single profile into multiple profiles

2
 Key Design Variables: Tolerances
Aluminum extrusions are produced
to close tolerances

Every process has its deviation from

nominal.

With castings, for example, it’s shrinkage

and draft.

For the aluminum extrusion process,

dimensional tolerances are more an
evolution than they are fixed.

Improvements in die construction and press

practices can provide for even tighter
dimensional tolerances than standard on
aluminum profiles.

For many applications, standard aluminum

extrusion dimensional tolerances have Courtesy of Werner Extrusion Solutions LLC
proven to be more precise than those for
most competing processes.
Key
KeyDesign
DesignVariables:
Variables:Tolerances
Tolerances
Tolerances
Tolerance tables, are available in Aluminum
Standards & Data published by The Aluminum
Association.

Source: The Aluminum Association

Key
KeyDesign
DesignVariables:
Variables:Tolerances
Tolerances

Solids ‐ Definition
The key – which are the critical dimensions?

• These?

Base of Gap Dimensions

Wall Thickness
Key
KeyDesign
DesignVariables:
Variables:Tolerances
Tolerances

Hollow/Gap Definition
… or these
• Hollow/Gap Dimensions - Column 4-9

Gap Dimension Hollow Dimension

Key
KeyDesign
DesignVariables:
Variables:Fabrication
Fabrication
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
KeyDesign
DesignVariables:
Variables:Fabrication
Fabrication
Fabrication
• Sawing
• Punching/piercing/drilling
• Machining
• Bending
• Welding
• Milling
• Tumbling
Key
KeyDesign
DesignVariables:
Variables:Fabrication
Fabrication

Bending
• 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-
Variables: Fabrication
Joining
The rapid increase in automotive aluminum content – and in multi‐material solutions
– has led to a dynamic evolution in material joining technology. In response, a
comprehensive Aluminum Joining Manual, has recently been developed.

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

Key Design Variables: Finishing

As soon as mill-finish aluminum is

exposed to the atmosphere, an • Mechanical Finishes
oxide layer begins to form at the
surface. • Pretreatment

For many applications, aluminum • Chemical Finishes

profiles require no more
protection than this thin, • Anodizing
transparent oxide film.
• Liquid Coatings
However, aluminum profiles can
be treated with a wide range of • Powder Coatings
finishes wherever additional
protection or an enhanced
appearance is desired.
 Key Design Variables: Finishing

Mechanical Finishes
• Available in a variety of
textures, produced by a variety
of mechanical methods, such
as:
– Sanding
– Polishing
– Grinding
– Buffing
Polishing machine: Emmebi Srl
– Blasting
 Key Design Variables: Finishing

Pretreatment
• Refers to a specific process used
to prepare the surface of the
aluminum profile for subsequent
finishing.
• For profiles to be liquid painted or
powder coated, this process
usually includes cleaning/etching
of the aluminum and the
application of a pretreatment
coating.
 Key Design Variables: Finishing

Chemical Finishes
– Etching
• Application of a caustic
solution
• Yields a frosted, silver-white
surface appearance
• Minimizes the effect of die
lines
– Bright Dipping
• Produces a very shiny,
specular (mirror) finish
• Almost always followed by Bright dip colored profiles
anodizing immediately after
the final rinse, both to protect
the smooth surface and to
present a wide range of
colors.
 Key Design Variables: Finishing

Anodizing
• Is not a coating; instead it is an
electrochemical process that
forms a durable, porus anodic
oxide layer on the surface of
the aluminum, adding to the
protection provided by its
natural oxide film.
• This allows aluminum profiles
to retain their metallic luster
while accepting durable and
vibrant color.
 Key Design Variables: Finishing

Liquid Coatings
• Include a broad range of
paints, such as polyesters,
acrylics, siliconized polyesters,
and flouoropolymers

• Available in a virtually
unlimited array of colors

• Two basic types of paint lines

– vertical and horizontal.

Vertical liquid paint line

 Key Design Variables: Finishing

Powder Coatings
• Provide a durable finish with
little or no use of solvents
• Gaining use where volatile
organic compounds (VOCs)
are problematic
• Show performance
characteristics similar to liquid
coatings when both are based
on the same resin chemistry
(e.g. a polyester powder and
liquid coating perform equally Multicolor vertical powder coating line
when subjected to the same
weathering and physical
property requirements).
Case
Case Examples
Examples
Often we end up breaking (or at least bending) the “rules” to meet particular
product challenges, striving to meet
multiple objectives.

From a raw materials perspective,

aluminum is often costlier* than
alternate materials per pound, e.g.:
• Global Carbon Steel Price : $714/MT
• Aluminum (LME): $1,838/MT

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

 Case
Case Examples
Examples Solar
Mounting
Steel Beam & Channel vs. Custom Aluminum Profile
Structure
13 feet long
with wind load of
128 lb/ft.

Four solutions were

reviewed, 3 steel
options and one
aluminum extrusion
option.

Because of
aluminum’s light
weight and high‐
strength‐to‐weight
ratio, the extruded
aluminum solution
offered the lowest
cost option – even
though the raw
material cost is
higher than steel.
And, aluminum is
corrosion resistant,
looks attractive and
is 100% recyclable,
adding to its value.

Source: Werner Extrusion Solutions

Examples of Aluminum Extrusions
Building & Construction Industry The extrusions used in this
skylight system incorporate
building-integrated photovoltaic
(BIPV) insulating glass
modules.

The system also uses an

extruded aluminum vertical
façade structurally supported by
aluminum extrusions, which
seamlessly combines with the
BIPV panels for a dramatic and
breathtaking effect.

The fully-integrated system

uses strong, load-bearing
aluminum extrusions to
construct a skylight/atrium
envelope that saves and
generates energy, while
enhancing building design.

Photos courtesy of
Schüco International KG
Case Example: Building & Construction
Edith Green-Wendell Wyatt Federal Bldg
Portland, OR

Challenge:
Renovate this 35 year old, 520,000 sq. ft.
federal office building to achieve dramatic
reductions in energy use and water
consumption.
 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

Architect: Cutler Anderson Façade: Benson Industries

Photos: Nic Lehoux
Examples of Aluminum Extrusions
Solar Energy Industry
Nevada Solar One
Concentrated Solar Power Plant
This 64-megawatt solar field is
concentrating the sun’s energy via
parabolic mirrors onto collection
tubes containing thermal oil, which is
heated to 800 degrees F and then
piped to a central conventional steam
turbine plant which runs generators
to produce electricity.

There is almost 8
million lbs. of
aluminum
extrusions in the
framework
supporting these
parabolic mirror
support structures.

Photos By Gossamer
Space Frames. Used By
Permission of Acciona
Solar Power
Examples of Aluminum Extrusions

Telecommunications Industry
 Extruded from 6061 alloy
Machined in a 5 axis CNC fixture
 Straightlined mechanical
finish applied
No anodic coating applied
Examples of Aluminum Extrusions
Transportation Industry
Strong, lightweight aluminum
extrusions are used in
transportation applications.
• Aluminum is only about 1/3 as
heavy as iron, steel, copper or
brass.
• Thus, in applications where
volume remains the same
regardless of metal used,
aluminum goes about three
times as far as the other metals. Classic Trailers, Inc.

Ford Motor Co.

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
Case Example: Automotive
Mercedes SL Floor Assembly
Objective:
• 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
Case Example: Automotive
Lincoln MKZ Panoramic Retractable
Roof

• 10,000 per year

• Existing design in steel, 28 parts, stamping-
intensive, requiring high investment

Objectives:

• Cost neutral
• 25% weight reduction
• Part count reduction for reduced
labor cost
Case Example: Automotive
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: Medical
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
Photos: Accuray multiple manufacturing steps and
yielding a relatively high cost
Case Example: Medical
• Approach
- Replace EDM steel coupling with an
~1.5”
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

Coupling as extruded • 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%

After fabrication

Credits: Alexandria Industries

Case example: Medical
Hercules Patient Positioning System™

• Issue
When caregivers have to reposition a
hospital or nursing home patient, it
often causes discomfort to the patient
… and possible discomfort or injury to
the caregivers. There is also a loss of
dignity for the patient and a drain on
multiple caregivers’ time.
• Objectives
Develop a system that could be used
with existing hospital beds that would
allow a single caregiver to reposition a
patient in 10 seconds with the push of
a button!
 Case example: Medical
• Approach
- Develop a compact drive assembly – the
1.4” Hercules Patient Repositioning System™ --
that can be added to existing hospital beds;
when activated, the drive draws a special
sheet into its aluminum housing, thereby
gently repositioning the patient.
- Utilize 7 custom extrusions to create the
assembly, maintaining a minimal footprint
while handling 600 in/lbs of torque
0.2”
• Results
- Ready acceptance by hospitals
- Winner, 2014 Medical Design Excellence
Award
- Winner, 2014 ET Foundation Aluminum
Extrusion Design Competition, Professional
Category

The Morel Company

Case Example: Lighting
Center Mount LED Lighting
Fixture
• Issue -- Develop a heat sink for a new,
array-style center mount LED light fixture
for Medical/Examination applications.
This application requires dimming from
10% to 100%, a 3700 lumen output,
60,000 hour life and electromagnetic
compatibility
• Objectives
- reduce mass
- preserve, or improve heat dissipation
effectiveness
- source in North America for supply
chain efficiency

Original heat sink

Courtesy of Almag Aluminum Inc.

 Case example: Lighting
• Approach
- Replace solid center hub with hollow
1.4” section with uniform wall center web to
0.4” ensure structural performance
- Replace solid sections to be drilled for
screw attachment with integral screw
bosses
- Utilize 6360 alloy for thermal
conductivity, and to facilitate high
tongue ratios and tight tolerances
Original part
• Results
Original heat sink - 47% weight reduction
- 4% increase in surface area, for
improved heat dissipation
- elimination of secondary drilling
operations, reducing total cost and
speeding manufacturing

Redesign
Courtesy of Almag Aluminum
Case example: Consumer Products
Apple Watch Sport

• Issue
– When developing the
exciting new Apple Watch
Sport, Apple designers
wanted a material that was
light, strong … and of
course strikingly attractive.

– Need for a strong casing to

withstand everyday use
Want to see more?
https://youtu.be/ibklpzKai‐o
Case example: Consumer Products
Apple Watch Sport

• Approach
– Their answer: aluminum extrusion
of a custom alloy.
– Apple worked with its suppliers to
develop a proprietary
Magnesium/Zinc alloy.
• Results
– 60% stronger, yet still meets
Apple’s aesthetic targets
– Improved performance and
appearance
– The resulting aluminum alloy is
extruded, machined, buffed, bead
blasted and then anodized to
create a case designed to look
smart over time.
2019 Aluminum Extrusion Design Competition

Entry Deadline: April 1, 2019

Open to:
• Students studying design, engineering, architecture or
related field
– Must be enrolled in and attending high school, college,
graduate school, trade or technical school

Learning Opportunity:
Apply what you've learned about design and engineering by
entering the International Aluminum Extrusion Design
Competition. It's an excellent opportunity for a hands‐on
learning experience with the potential for professional
recognition and earned scholarships.
2019 Aluminum Extrusion Design Competition
Student Class Scholarship Awards
Enter the competition to receive the recognition you so
richly deserve; gain pride and a sense of accomplishment.
And, of course, there are the scholarships totaling $8,500!

Student Class Scholarships:

1st place $3000
2nd place $2000
3rd place $1000
Bonnell Sustainable Design Award: $2,500

Student scholarships are sponsored by:

www.Bonnellaluminum.com
 2019 Bonnell Sustainable Design Challenge
The Bonnell Aluminum Sustainable Design Award will be offered in addition
to the First‐, Second‐, and Third‐Place Scholarship Awards. The award will be
presented to the entry that, in addition to the four basic competition judging
criteria, also addresses the following:

• Design must be a viable extrusion‐based product that meets the demands

of the environment while contributing to the quality of life for its intended
users
• Entry addresses the technical aspects of extrusion design:
– Demonstrates the entrant’s knowledge and application of aluminum
extrusions
– Designer takes into consideration the limitations of the extrusion process.
• Quality of the design aesthetics in the intended target market place.

For details visit www.ETFdesign.org

Aluminum Extrusion Design Competition
Past Winners
2018 First Place ‐ $3,000 Scholarship
• “N‐FORMER” – Outdoor
interactive informational
box
– Solar powered with
touchscreen and speaker
– Built‐in adjustable height
feature
• Sydney Smith, ; Purdue
University, West Lafayette,
Indiana
Aluminum Extrusion Design Competition
Past Winners
2017 First Place ‐ $3,000 Scholarship

• “AXIAL” – Bike cargo

rack
• Garen Gibbs, ; Purdue
University, West
Lafayette, Indiana
Aluminum Extrusion Design Competition
Past Winners
2016 First Place ‐ $3,000 Scholarship
• Dynamic Arm Support
Apparatus (DASA)
• Aubree DeLozier,
Christopher Sylvester,
Stephon Giscombe,
Rachel Hernandez, Brad
Clark
• University of Alabama –
Huntsville
Aluminum Extrusion Design Competition
Past Winners
2018 Second Place ‐ $2,000 Scholarship

“Extension” Prosthetic Device for Musicians

Tessa Barnes; Southern Illinois University, Carbondale, Illinois
Aluminum Extrusion Design Competition
Past Winners
Bonnell Aluminum
2018 SUSTAINABLE DESIGN AWARD
$2,500 Scholarship

BLADE– user‐friendly aquaponics system

Jon Beldner; Purdue University, West Lafayette, Indiana
Aluminum Extrusion Design Competition
Past Winners
2018 Third Place ‐ $1,000 Scholarship

“Foldo” Folding Wheelbarrow

Bheumsoo (Kyle) Kim; Purdue University, West Lafayette, Indiana
Aluminum Extrusion Design Competition
Past Winners
2018 High School Honorable Mention
$500 Scholarship

“AlumShoe” Aluminum Track for Vehicles

Emma Jacobs; Sherwood High School; Sherwood, Oregon
2019 Aluminum Extrusion Design Competition
• More information at www.ETFdesign.org
– Website contains contest details, design resources, and more.
– Download the Call for Entries, including Entry Form from the website

• Entry Deadline: April 1, 2019

• General aluminum extrusion information and resources: www.AEC.org

Conclusion
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
Additional Resources
For more Information and Training

Purchase the Aluminum Design Manual Utilize ASCE Aluminum Design Manual
2015 edition from the Aluminum training
Association (aluminum.org)

– go to www.asce.org/continuing_education/
Under “My Learning” choose “Browse
course catalog” and search for “2015
Aluminum Design Manual” to see a list of
“Aluminum Structural Design with the 2015
Aluminum Design Manual” courses.

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
Additional Resources
For more Information and Training
• Utilize the Aluminum Extruders Council
website (aec.org) for webinars or other
key information

• Extrusion Applications
• Extrusion Design Resources
• Sustainability Info
• Find an Extruder search
• 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 AEC Aluminum
benefits, design and technology to users, product designers, engineers
and the academic community. Further, AEC is focused on enhancing the
AEC Buyers’ Guide Extrusion Manual
ability of its members to meet the emerging demands of the market (www.AECguide.org) (www.AECmanual.org)
through sharing knowledge and best practices.
Sample Q&A