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Aerospace & Defense Extrusion 24 Nov 2025

Metal Extrusion

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updates@lform.com

How Does Metal Extrusion Work?

01 Design Preparation

The process begins with the creation of CAD models for both the part and the die. For the part, key requirements are load capacity, appearance, material and tolerances. For die design, the opening must match the desired cross section (shape). The land region, the portion of the die that finalizes the shape as the material exits, must be well defined. Flow simulations are recommended to predict material behavior and prevent dead zones or tearing.

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02 The Process

Billets are cut to the required length from bar stock. After loading in the pre-heated, a hydraulic arm forces the billet through it. As the metal emerges from the die, it takes on the shape of the die opening, forming a long, continuous profile. The extrusion is then cooled and moved to a stretcher, which straightens it to correct any twisting or bending. Finally, it is cut to the proper length for further processing.

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03 Post-Production

Cut extrusions are moved to an aging oven, where they are heated to a controlled temperature. This heat treatment process significantly improves the extrusion’s strength and hardness. Additional processes like anodizing and powder coating may be added to improve their appearance or provide corrosion protection. Drilling or machining may also be performed to prepare it for its final application.

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Is Metal Extrusion a Fit for Your Business?

Advantages

  • Complex, Uniform Shapes

    Metal extrusion can create long parts with intricate cross-sections that would be difficult or impossible to machine. The consistent flow of material through the die ensures the shape remains constant.

  • Reduced Waste

    Most of the billet material becomes part of the final product, reducing scrap and improving cost efficiency. Savings can be substantial on high-volume projects.

  • High-Quality Finishes

    The pressure and controlled metal flow results in smooth surfaces and precise dimensions. This often reduces or eliminates the need for additional finishing.

  • Improved Mechanical Properties

    Aligning the metal’s grain structure with the direction of the extrusion increases strength. This directional grain flow is essential in structural and load-bearing applications.

  • Varied Materials and Shapes

    A wide range of metals can be utilized, including aluminum, copper, steel and magnesium alloys. Extrusion can produce everything from simple rods and tubes to highly complex profiles.

  • Ready for High Volumes

    Extrusion is well-suited for continuous manufacturing, allowing long lengths of product to be produced in a single run. This efficiency reduces production time and improves consistency, making it ideal for high-volume applications.

Disadvantages

  • High Initial Costs

    Designing and creating metal extrusion dies can be expensive. This makes it impractical for small production runs and prototype work.

  • Careful Monitoring

    Excessive friction or uneven heating can cause surface defects, tearing or dimensional inaccuracies. Careful monitoring of processes and lubrication are essential for consistent extrusion quality.

  • Material Limitations

    Not all metals are equally suitable for extrusion. Some high-strength alloys are difficult to process and may require higher pressures, specialized equipment or alternative forming methods.

What Applications Are The Best Fit For Metal Extrusion?

Industries that require strong, precisely shaped components often utilize metal extrusion. They also benefit from long production runs that minimize costs.

Construction

Metal extrusion is often used to create structural components for the building industry. Products include door frames, roofing panels, beams, channels and supports – which all require uniform cross-sections for easy assembly.

Automotive 

Aluminum extrusions are commonly utilized for chassis components, bumpers and engine parts. Extruded tubes serve as safety reinforcements in vehicle structures.

Electronics

Copper and aluminum extrusions are employed for cable conduits and heating components. Their complex cross-sectional shapes ensure efficient current flow and heat dissipation.

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Metal Extrusion – Additional Resources

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Why Choose Fathom for Metal Extrusion

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