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Jackie Kelly

What are the Benefits of Aluminium Extrusions?

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Aluminium profiles play an essential role in many of today’s modern industries including aerospace, electronics and engineering. For this reason, a high-quality service that is guaranteed to provide accurate results is essential when sculpting aluminium parts. Aluminium extrusion is the process of transforming aluminium alloy into objects with a definitive cross-section profile. It is also a process that makes the most of aluminium’s unique combination of physical characteristics in a way that allows for a wide range of results to be achieved.

So, why is aluminium extrusion the way to go for sculpting aluminium parts?

Range of design options

One stage of the aluminium extrusion process involves design work, during which an accurate design plan is created that will be used to ensure accurate results from extrusion. During this stage, CAD technology is used to produce a high definition image either in 2d or 3D so that you can visualise the end product from the very start of the extrusion process. This allows room for early alterations to the extrusion plans if you see fit, ensuring that there will be no disappointments at the final stage.

Cost efficient

Aluminium extrusions require less bespoke tooling than alternative manufacturing methods, allowing for the cost of production to be kept to a minimum, whilst still producing excellent results.

Wide range of finishing options

There is a wide range of finishing options available to ensure that your aluminium parts are made to the best standard that they can be. Your finishing options include punching, CNC machining, brushing, cutting to length, drilling, tapping, forming or aluminium anodising services simply depending on your individual needs. This is done through a very precise system to ensure that all finished products are fully functioning and ready to be used upon finish.

Can produce a wide range of shapes and sizes of aluminium parts

During aluminium extrusions, a die-cast is made to determine the shape and size that the aluminium will take when it is heated. This die is designed to mould the aluminium into the shape you need it to be and there are many options when choosing the shape and size of your die cast to ensure you achieve the exact results you want. These die casts are either hollow or solid. A hollow die is an extrusion that has single or multiple hollows in its shape. It is a more complex die structure, consisting of two parts that create the outer and the inner shape. A solid die, on the other hand, is designed to produce an extrusion with no hollow areas in it. This is a simple, one-part die resembling a template. 

Who to contact?

At Love Aluminium, we are here to help those looking for aluminium extrusion services. To ensure that our customers achieve the results that they want without any compromise, we maintain constant communication from the concept stage all the way to delivery. We are equipped with the highest quality aluminium extrusion supplies to achieve the excellent results that you are looking for. Please do not hesitate to get in contact for more information.

Run out table showing fans for cooling

Aluminium Extrusion: What is involved in the process?

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Aluminium is a lightweight but strong and durable material – very design-friendly. With the right quality of service carried out by professional aluminium extrusion suppliers, it is easily possible to produce impressive and reliable results using aluminium. That’s why aluminium extrusion is a specialist service relied on by many manufacturing industries across the world to create their products.

The aluminium extrusion process is made up of three stages, all of which are essential to ensure that you achieve the results that you are hoping for. These stages are the design stage, extrusion, finally, the fabrication and finish stage.

The Design Stage

During this stage, CAD technology is used to give you a high definition image of the potential finished product from the very start of the design process. At this stage, you will be able to make any alterations to your design if you see fit. These CAD images can be processed from even a simple sketch, so no one need miss out on this important stage. Being able to visualise the finished product from the start of the aluminium extrusion process will have huge advantages in getting you the results that you want, allowing you to make informed decisions throughout the other design stages.

The Extrusion Stage

Aluminium extrusion is defined by the heating of aluminium and pushing it through a die. This die is designed to mould the metal into the shape and size that you require it to be. There are two types of die: the hollow die and the solid die. A hollow die is an extrusion that has single or multiple hollows in its shape and is a more complex die structure, consisting of two parts that create the outer and the inner shape. A solid die, on the other hand, is designed to produce an extrusion with no hollow areas in it. This is a simple, one-part die resembling a template.

Once the die has been created, aluminium is then heated to a temperature between 350-500°C and pushed through the die to create the desired shape using either a high-pressure ram or hydraulic press. The malleable properties of aluminium allow for it to be moulded excessively without any breakage or damage to the metal during the aluminium extrusion process, to the extent that when pushed through the die the aluminium can be stretched to lengths of beyond 40 metres. Whilst passing through the die, the aluminium is moulded into shape to become a piece of its own that can be joined to other corresponding pieces and added to the structure you are working on.

Fabrication and finish

If required, the fabrication and finish stage can involve several processes including punching, CNC machining, brushing, cutting to length, drilling, tapping or forming – all depending on the needs of the client. This method is done through a very precise system to ensure that all finished products are fully functioning and ready to be used by our customers.

The fabrication and finish stage might also include aluminium anodising services, a process during which an additional layer of external protection is added to the aluminium through a durable oxide layer whilst also giving it a finish with a more aesthetically attractive surface. This process is typically recommended for creating metal parts that might be subject to more wear through harsher external environments.

Here at Love Aluminium, we are aluminium extrusion suppliers able to offer all of the above services. Why not contact us today to discuss your project specifications and requirements to see how we can help you? Whatever aluminium project it is that needs working on, we are bound to have a service to suit your needs.

Aluminium Extrusion

How Can Aluminium Extrusion Profiles Be Finished?

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Sometimes a client may want the surface of their aluminium profiles to be more extensively prepared than is available straight from the die. This may simply be to improve the appearance of the profiles, or because the aluminium’s surface needs adapting to the requirements of certain industries, such as agriculture or pharmaceuticals. That’s why here at UK Profile Components Ltd we offer a range of finishing treatments as part of our aluminium fabrication process.

Our aluminium profiles can be treated with a variety of finishes. The type of finish chosen depends on the customer’s industry and their individual requirements. There are three main types of finishes that we can provide for aluminium extrusion profiles. Here is some more information about each of the processes we offer to our customers:


Although it is a relatively soft metal, aluminium is a naturally strong and durable metal that can stand up to significant scrutiny. That makes aluminium receptive to more mechanical methods of surface preparation. Our aluminium extrusion profiles can easily be altered by using abrasive methods such as polishing and buffing. These are simple processes that can brighten the surface of the aluminium and make it more appealing.


Aluminium is a metal that boasts excellent corrosion resistance, leaving its structural integrity generally unimpaired by atmospheric attack. This makes it an ideal material for anodisation. The metal is anodised by its being immersed in diluted sulphuric acid, thickening its natural oxide layer. This can create a highly aesthetically pleasing effect as well as providing the metal with greater protection.

Anodisation can be combined with polishing to brighten the metal and give it a mirror finish like chrome. Natural satin silver is the most popular and inexpensive option when anodising aluminium extrusion profiles. However, it is also possible to perform coloured anodising in a wide range of colours from dark colours such as black and bronze to brighter primary colours, gold and the popular rose gold.

Powder coating

Finally, powder coating is a surface treatment which is essentially the application of paint without any solvent element. This process gives the profiles excellent UV protection, making it ideal for profiles to be used outdoors such as those in architectural applications and signage. When applied correctly, powder coating is a very durable surface treatment, potentially lasting on the surface of the metal for between 15 and 20 years.

Questions? Contact us!

Anodising sustains the ‘metal’ appearance whereby powder coating masks it, however the effects of each treatment should be considered when deciding on which finish to apply. We also recommend the consideration of other factors, such as the lifespan of the treatment and resistance to abrasion before seeking any surface treatment.

Here at UK Profile Components, we can provide you with extensive advice on our finishing treatments, whatever your individual requirements. Whatever type of finish you are seeking for your aluminium extrusion profiles we can provide you with the solution. Please don’t hesitate to get in contact with us today and we’d be delighted to provide you with the right finishing for your industry.


How aluminium extrusion works – from start to finish

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As one of the most thorough aluminium extrusions suppliers in the UK, here at UK Profile Components, we aim to make the aluminium extrusion process as easy as possible for our customers who hail from a wide variety of different industries.

Aluminium extrusion is an extensive process consisting of several stages, which is why it can occasionally be difficult to explain. For those who are looking to learn more, here is an explanation of our five-step aluminium extrusion process from start to finish.


The initial stage of aluminium extrusion revolves around design with our using computer aided design (CAD) to plan how a customer’s brief can be turned into a physical creation.

Using our computers to create sketches and drawings, we will develop a clear picture of what the final product will look like along with the measurements necessary to create it. This allows us to monitor the process, making tweaks where necessary to ensure that our design is to the customer’s satisfaction before proceeding.


Once the design of the aluminium extrusion has been completed and approved, we will then go on to create the die for the profile. An aluminium extrusion die is a steel tool through which aluminium is pushed with force, leading it to exit the other side of the die in the shape and size desired.

We can use profiles using standard existing dies capable of producing several tonnes of extrusions, or a bespoke die to meet clients’ individual needs.


Once we have created the die to be used, performing the aluminium extrusion itself is a relatively straightforward process. In the extrusion process, an aluminium alloy is heated to 350-500 degrees before being pushed through the die at pressures. This allows us to create aluminium profiles of up to 42m which are then pulled from the die. These profiles are then cut to whatever length the customer has requested.


Sometimes a client may demand a more desirable appearance or a better surface preservation from their aluminium profiles than that which is available straight from the die. One common reason for this is to adapt the aluminium for the specific needs of certain industries such as agriculture or pharmaceuticals.

Should the customer request this option, we can then treat the aluminium with a range of finishes. The most common types of finishing we provide for aluminium profiles include mechanical (abrasive finishing methods such as polishing and buffing), anodising (immersing the profile in diluted sulphuric acid) and powder coating (paint without solvent, ideal for extending the life of the aluminium and giving it extra UV protection). The type of finish chosen depends on the customer’s individual requirements.


Once the aluminium extrusion process is completed, we will hold stock in our warehouse for clients to call off as required. Delivery from our stock warehouse typically takes between two to three days. We are happy to provide our clients with regular updates on stock levels with each stock movement so they can plan their processes accordingly.

Interested? Let us know!

If you would like to know more about our aluminium extrusion process, why not get in contact with us today? We’d be happy to offer you advice and a price estimate before we get straight to work on your design.

Aluminium Extrusion

FAQs about Aluminium Extrusions

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Here at Love Aluminium, we aim to be one of the best aluminium extrusions suppliers in the UK, offering quality aluminium extrusion profiles to our customers at a competitive price.

With our clients hailing from a variety of industries, we occasionally receive questions from our customers looking to know more about us and the aluminium extrusion process. For ease of response, here are answers to some of the questions we are most frequently asked most frequently asked questions.

How does the aluminium extrusion process work?

As aluminium is a soft and malleable metal, it lends itself excellently to the process of extrusion. This process, which creates aluminium extrusion profiles either in solid shapes or with a complex network of cross sections at their centre, is excellent at creating parts for a diverse range of products used in dozens of industries.

In the extrusion process, aluminium is heated to extremely high temperatures between 350 and 500 degrees Celsius. The semi-molten aluminium is then forced through a specially cast steel die using a hydraulic press, allowing it to take on the die’s unique shape.

The result of this process is an aluminium component that can easily be joined to others with corresponding features, for example, a T-slot which allows bars to be joined together perfectly.

What can aluminium extrusion be used for?

The versatility of aluminium extrusion is what enables it to be used to create parts for industries across the world. Profiles can be made using existing standard dies to produce common parts such as round tubes, bars, and angles, or profiles can be customised using bespoke tools to meet clients’ individual needs. Those tools will have been made using computer aided design (CAD) and computer aided manufacture (CAM).

Aluminium profiles’ usefulness across a variety of industries has led them to be found in a huge variety of products, from agricultural to automotive applications. They also play an essential role in industries such as aerospace, electronics and engineering.

What are the advantages of aluminium extrusions?

The aluminium extrusion process brings with it a wealth of advantages. Perhaps the main advantage is that because certain shapes are extremely common, extrusion requires fewer bespoke tools than alternative manufacturing methods and therefore, comes at an extremely attractive price.

As it is one of the most cost-effective methods of achieving a range of shapes and sizes, aluminium extrusion is ideal for shorter projects such as trials and prototypes, offering companies the opportunity to test complex product designs affordably.

Contact us!

With our thirty years’ experience of the aluminium industry, we hope that we have outlined why you have stumbled upon the best aluminium extrusion suppliers, right here at UK Profile Components.

If you still have any questions about our extrusions process, why not get in contact with us today via our contact page? We’d be happy to offer you help, advice and a price estimate for any extrusions before supplying.  We can also offer a stockholding service whereby we hold your bespoke extrusions in our warehouse for delivery within 2-3 days of call off.

Aluminium Extrusion

Four Key Advantages of Aluminium Extrusion

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The importance of aluminium extrusion to industries such as manufacturing and construction cannot be underestimated. Aluminium extrusion has applications in fields such as engineering, electronics and aerospace, meaning that its influence can regularly be found in everyday life.

One high-profile demonstration of aluminium extrusion’s influence can be found in the recent news that the train operating company Merseyrail has contracted the Swiss manufacturers Stadler to provide its new £460m lightweight aluminium train fleet.

While we have explored the extrusion process in detail in one of our most recent blogs, it is worthwhile outlining the most appealing factors of aluminium extrusion to explain why businesses rely on it so much. Here are a few of the key reasons why aluminium extrusion is so vital:

Competitive price

Aluminium extrusion requires less bespoke tooling than more traditional manufacturing methods, making the cost of completing aluminium profiles very affordable for manufacturing or construction businesses. These profiles are often created in conjunction with standard aluminium extrusion dies to produce common shapes like tubes, bars or angles, although more bespoke dies can be created to meet the needs of individual manufacturers. Either way, it is an affordable process.

Suitable for trial runs

Due to their low cost of production, aluminium extrusion profiles are perfectly suited for the use of product trials and prototypes. This enables companies to examine the real-life result of the project after it has been designed by computer, allowing them to see any problems posed by complex shapes and sizes and refine the design for another run. We have plenty more information about our CAD design and aluminium die creation services on these pages here and here.


As mentioned above, the aluminium extrusion process is regularly used in a wide range of industries including aerospace, electronics and engineering – in our most recent blog, we even outlined a few of the more surprising household objects created by extrusion including glass bottles, cars and wires and pipes. The lightweight nature and affordability of aluminium makes it a versatile material that is suitable for a myriad of applications.

Easily connectable

The often uniform nature of aluminium extrusions makes them ideal for creating pieces that can be easily joined to others with corresponding features. For example, T-slots created by aluminium extrusion enable manufacturers to join bars together using special connecting pieces that fit into the cavities. For that reason, extrusion is ideally placed to support complex construction projects.

Here at UK Profile Components Ltd we are proud to specialise in designing and creating aluminium extrusions for industries all of the world. Why not get in touch with us today via our contact page to see how we can help you with your extrusion requirements?

We will handle your extrusions with care and deliver them on a dedicated vehicle directly to your chosen destination within two or three days from call off for material held in stock, or we can supply them directly from our the extrusion mill. Whatever your extrusion needs, we will be able to meet them.

Aluminium Extrusion

7 Household Objects You Wouldn’t Have Realised Are Made with Extrusions

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Lots of people outside of the industry wouldn’t have the first clue when it comes to what an ‘extrusion’ is, let alone the fact that they are used in a multitude of industries. From our speciality, aluminium extrusions, to surprising industries like food production, the process crops up in many unsuspected places.

Here are seven household objects that you wouldn’t have thought were created by extrusion methods:

Drinking Bottles

Some drinking bottles are manufactured by extruded blow moulding, which involves the process of pushing plastic through an extruder die, closing a mould over the plastic (called a parison), then the parison is inflated with a blow pin and compressed air. Finally, the parison is trimmed at both ends to make it into a bottle.


Often made out of stainless steel extruder dies, the machine that makes pasta operates by mixing the ingredients in one end, then pushing the mixture through the extrusion. The die is catered to the type of pasta required – from macaroni, to fusilli – then, if the pasta is in short bits like penne, cut with a rotary blade to keep pieces at the same length.

Dog Food

Most brands of dog food are used by extrusion methods, including Bakers Complete, Royal Canin Dry and Pedigree Complete, in a similar method to that of pasta. The only difference is that the little kibbles start out as dough, which is passed through the die extruder, and then expands with the pressure and heat of the machine – making what we know as dog food.


Due to its lightweight qualities, aluminium is being used increasingly with the manufacturing of automobiles. For example, Audi are branching into aluminium extrusions for their cars’ body structure, to create their line of hybrid aluminium models.


Household carpets are created by an extrusion method, although not quite in the same way as the other examples here. The fabric fibres that make up the bulk of the carpet are made by being passed through an extrusion die, then spun to make them stick together enough to be attached.

Plastic Bags

Similar to the glass bottles, plastic bags are created in a process called blow extrusion, where the plastic is heated then manipulated using compressed air to form the bag shape. Afterwards, the bags are cut to shape with machinery.

Wires and Pipes

One of the more predictable of the products made with extrusion methods, household and industrial wires and pipes are created by feeding the material through a die in an ‘o’ shape, allowing for wires to fit through or pipes to have space for inserting things into.

The opportunities are endless when it comes to extrusion methods, which is why we’re so committed at Love Aluminium to creating bespoke aluminium extrusions for a wealth of purposes.

Contact us today to see how our company can help you with your aluminium extrusion requirements, as large or small as the project may be – one of our specialist advisors will be happy to take your call.

Mersey Rail

Liverpool Merseyrail Closes Deal for £460m Aluminium Extrusion Train Fleet

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Due to be rolled out throughout the Merseyrail line by 2020, a completely revolutionised design of underground train fleet has been confirmed by Swiss contractors Stadler this month.

The 75-year-old rail construction company has worked on a wide portfolio of large scale projects, with trains manufactured by Stadler running in 28 countries worldwide to this date. With the creation of this new deal, there will 200 UK jobs set up by 2021, bringing the collective workforce up to over 7,000 employees.

The Pros

Made of lightweight aluminium extrusions, the trains will be considerably faster than the current 40-year-old carriages currently in use, with a reported decrease in journey times of 10% and upwards. Travelling at a maximum speed of 75mph, the fleet will ensure that Liverpool’s commuters are where they need to be, when they need to be there.

Other benefits of the upgrade come in the increase of capacity due to the 60% increase of size, meaning that up to 486 people could travel on one of the four carriage trains. This 60% increase will cut congestion and waiting times, allowing for a smoother underground experience.

Optimising for accessibility and wheelchair friendliness, the new trains will be significantly lower down compared to their current counterparts, sitting at a mere 960mm above rail level. This completely walk-through design will make it easier for solo disabled travellers and again, cut journey times.

Following the deal signing, construction is now ready to take place, with plans to create the first of fifty-two trains by 2019, which will then all be implemented by the time 2021 rolls around.

The lightweight carriages are designed to be airy and spacious, without dividing doors and the installation of CCTV for the driver to monitor – although some have questioned this decision, suggesting that making the driver keep an eye on CCTV will distract from the actual driving.

The Cons

There hasn’t been a shortage of complaints following the reveal of the custom aluminium extrusion train, with the subsequent announcement that up to 220 jobs will be lost due to the vehicles being driver-operated only.

Additionally, members of the public have voiced their concerns at the prospect of having a train operating as driver-only, suggesting crime rate increases and a general lack of safety.

The Chief Executive of Merseytravel, Frank Rogers, says of the project: “We are very much looking forward to working with Stadler. The fleet of new trains will provide the foundations of our City Region’s long term rail strategy and we anticipate our relationship with Stadler developing into a strong, enduring partnership”.

If you would like to find out more about aluminium extrusions and how they could benefit your business – perhaps not quite as large scale as a whole fleet of trains – Love Aluminium have over 30 years of experience in the industry and can advise you on the best practices for designing with aluminium. Contact today to book in for a consultation with the specialist team.

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What is an Aluminium Extrusion and What are They Used For?

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Aluminium extrusion is the process of forcing a substance – in this case aluminium – through a press with shaped apertures cut out of it. This means that the aluminium will take the shape of the aperture and you will end up with a long bar – as long as your piece of aluminium will allow – of aluminium in the desired shape. This long extrusion, known as an aluminium profile, can then be sliced, rather like a loaf of bread, into many smaller lengths, all having the requisite shape and size.

The aluminium is shaped using dies which are tools cut from sturdy steel, into the void of the desired shape. During the process the aluminium is fed into a ‘holding chamber’ called a container. Pressure is applied from behind the piece of aluminium which slowly compresses to fill up the space inside the container. After this, the pressure continues and there is nowhere for the aluminium to go except through the relatively small aperture in which the die is situated, shaping the aluminium as it squeezes through.

The piece of aluminium fed into the extruder is called a billet. The billet must be heated up in order to become malleable enough for the extrusion process without suffering molecular damage. The heating process also plays a part in tempering the aluminium profiles, readying the metal for use in industrial processes or plant building, making it a dual benefit. Following extrusion, the aluminium can be treated according to the needs of the industry in which it will be used, before one of several cooling techniques are applied.

The advantages of using the extrusion process is obvious: it is a quick and easy way to form the aluminium into the desired shape. Also, there is little wastage, as there would be if a stamp press was used – think leftover dough from cutting out biscuits: when the ‘dough’ is aluminium which would need to be remoulded, retreated and reprocessed in order to cut out more shapes, the expense soon adds up.

Another advantage is that once the extrusion machine is engineered, the same result can be achieved over and over again. The die, once created, can be used over and over again, quickly paying for the expense of die-making and becoming more and more profitable over time.

Which industries can benefit from using the extrusion process? Almost any business that needs to supply or use parts that are made from aluminium! Aircraft and vehicle parts can be made from aluminium, industrial sewing and manufacturing machinery will benefit from spare parts being engineered to exact specifications and so on – there are few industries that will not benefit from the aluminium extruding process in some way. Even those businesses that will not need a huge throughput of aluminium parts can still benefit from the process: once the die is made it will last until it is needed again, and will not cost any more money than the price of storing it safely until it is due to be used.

Aluminium extrusion is a relatively simple process, one that can supply any business with the parts they need. Just call us today, tell us your aluminium needs and let us guide you through the whole process showing how your needs can be met.

Aluminium Extrusion run out table

Custom Aluminium Extrusion Design from UK Profiles

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Aluminium offers manufacturers the advantage of creating complex shapes through the process of extrusion, which has allowed the production of parts for numerous applications. In agricultural, automotive and engineering industries, aluminium components play a critical role in developing functional devices. The ability to have components in particular shapes negates the need to have secondary joining procedures as is common with other metals such as titanium. Pure aluminium is an excellent material for extrusion, but it is usually blended with other metals to capitalise on the properties of the two or more compounds used.

Designing is the greatest part of the extrusion process because it allows manufacturers to have parts that are accurate in shape, size and weight, thereby improving quality. With a custom aluminium extrusion design, a company can ensure that its products are unique and suitable for their corresponding applications. The extrusion process involves pushing an aluminium alloy through a die that is designed in the required shape and then applying extremely high pressure. Our extrusion process results in aluminium profiles as long as 42 meters, which can be cut to meet the necessary lengths.

Cost Effectiveness

A custom design for your aluminium extrusions come with great costs savings. For large companies with high demands for aluminium products or components, the low expenses associated with the extrusion process reduce manufacturing budgets significantly. When working with other metals, you need to invest in advanced machinery for various procedures like cutting and shaping. These devices can overrun the production costs to enormous amounts, and it is even worse when working on long-term projects because there are maintenance expenses to consider. The malleability of aluminium allows it to undergo extrusion without the need for complicated machines.

Another money-saving aspect of aluminium extrusions is the simplicity of the process. Due to the lack of extensive secondary procedures to shape aluminium components, production costs are lower than those incurred when working on a material like steel where joining processes are required to create extrusions. All machining operations that are carried out after the primary process are uncomplicated.

A custom aluminium extrusion design minimises costs because less material is used during manufacture. The extrusion process makes it possible only to develop parts that are necessary for the functionality of a device. Because of the precision aspect of the process, wastage of materials is minimal, and it all leads to a considerable reduction in overall expenses.

Unlimited Opportunities

The extrusion process makes sense for most companies because it presents numerous product varieties. With the personalisation options available when designing aluminium extrusions, you can order all kinds of products. Whether an application requires solid profiles, soft lines, cavities, deep channels or uniform walls, the extrusion process can provide it. We have fabrication processes for clients who need them to fine-tune their aluminium extrusions. Finishing is not a must-have step on aluminium due to its high corrosion resistance, but you can choose to power coat or anodise components for aesthetic.

When picking finishing methods; factor in the resultant effects on the material and its recyclability. Decorative patterns also increase the versatility of aluminium extrusions. You can identify several patterns to use on your components to provide consumers with more alternatives and establish an image for your businesses in the process. By picking one decorative pattern and using it consistently, consumers will come to associate it with your products, and that is an excellent way to market.

Designing aluminium extrusions requires creativity, and with our help, you can get custom varieties for your company. Our aluminium extrusion process capitalises on the great properties of the metal to simplify assembly, reduce finishing and improve production times.