Aluminum extrusion design allows for sleek profiles, light strong sections, and an almost endless array of custom shapes. But to fully exploit the advantages of aluminum extrusion, more than creativity is required: one needs Design for Manufacturability (DfM).
DfM is simultaneously the art and science of designing products so that they can be efficiently manufactured without sacrificing functionality, performance, or aesthetics. In the design of aluminum extrusions, this involves knowledge in how design geometry, material behavior, and process limitations interact within the extrusion process.
At Can Art Aluminum Extrusion, we work with designers and engineers to close the gap between imagination and manufacturability, helping you optimize every design for performance, precision, and cost efficiency.
Following are five key DfM principles that every engineer and product designer should follow when working with aluminum extrusions.
Simplify Profile Geometry: The Power of Design Simplicity
While complex shapes may look impressive in CAD, simplicity is strength where extrusion is concerned. Each bend, tongue, hollow, and undercut adds another layer of complication to the die that can compromise the quality of the extrusion, raise the cost, and restrict the tolerances.
Key Aluminum Extrusion Design Tips:
- Geometry should be uniform and balanced. Symmetrical profiles extrude more evenly.
- Avoid any deep hollows and voids that are not functionally necessary.
- Control tongue ratio: the lower this ratio, less than 3:1, the better the die stability and hence less possibility of breakage.
- Avoid sharp corners; instead, use at least 0.5–1 mm radii for smoother metal flow.
- Where possible, combining several parts into one extrusion will make later assembly much easier.
Pro Tip: If you have multiple cavities or interlocking shapes, it’s often best to start working with your extruder upfront. A collaborative DfM review can identify cost-saving alternatives before the die is built.
2. Maintain Uniform Wall Thickness for Better Metal Flow
One of the golden rules when it comes to designing aluminum extrusions is to have uniform wall thickness. Variable wall thickness results in variable metal flow during extrusion, which can result in warping, surface defects, or dimensional inaccuracies.
Best Practices for Wall Thickness:
- Keep the wall thickness of the profile consistent for uniform cooling, which ensures dimensional stability.
- Where variable thickness cannot be avoided, the transition should be gradual without any abruptness.
- Minimum wall thickness of aluminum extrusions usually ranges from 0 to 1.5 mm, depending upon the alloy, design, and application.
- Thicker walls will lead to weight increases and thus cost, so balance strength with material economy.
Question Answered:
What is the minimum wall thickness for aluminum extrusion?
Most structural or architectural profiles can have a section thickness in the range of 1.0–1.5 mm, though high-strength applications may require thicker sections.
3. Design for Cost Efficiency and Post-Extrusion Processes
Every design decision affects manufacturing cost, not just in extrusion, but in machining, finishing, and assembly. DfM encourages you to consider the total lifecycle cost right from the start.
Cost Reduction Strategies:
- Minimize machining by incorporating design features in the profile, including grooves or channels.
- Avoid excessive hollows requiring complicated multi-part dies.
- Use standard extrusion dies wherever possible, or modify existing ones where feasible.
- Design for post-extrusion finishing: surfaces should enable easy anodizing, powder coating, or polishing.
- For assembly integration, add screw bosses, snap fits, and interlocking joints to reduce the need for hardware or welding.
Pro Tip: Consider more than just the extrusion. A profile that is easier to assemble or finish can yield bigger cost savings than just reducing wall thickness alone.
Account for Tolerances and Dimensional Accuracy
Every extrusion process has natural limitations to dimensional precision. Understanding these tolerances helps ensure your design performs as expected while remaining manufacturable.
Tolerancing Guidelines:
- Base tolerances according to AA (Aluminum Association) or EN 755-9
- Tight tolerances increase production costs, use them only in functional areas.
- Allow for thermal expansion and contraction, especially for long profiles.
- Machining or secondary operations on critical assembly parts should be performed after extrusion to achieve tight fits.
Common Extrusion Design Considerations:
- Profile complexity: More complex shapes have wider tolerances.
- Die wear and temperature: Affect long-term dimensional consistency.
- Extrusion direction: Align key dimensions with the flow direction for better accuracy.
Discussion Question Answered:
How do you design for aluminum extrusion?
With uniform walls, simple geometry, real-world tolerances, and early collaboration with your extruder, every design feature can be produced and finished consistently.
Optimize for Assembly, Strength, and Material Performance
A well-designed extrusion doesn’t just look good, it fits, functions, and lasts. DfM extends into assembly and structural performance, where design choices impact product integrity and usability.
Assembly and Structural Design Principles:
- Include fastening features like screw bosses or snap fits for easier joining.
- Choose materials wisely: 6000 series alloys such as 6061 and 6063 provide excellent strength, machinability, and surface finish.
- Validate structural integrity and load paths using finite element analysis (FEA).
- Design profiles that avoid stress concentrations by rounding internal corners.
- Consider the dimensional accuracy of mating parts to ensure proper fitting during assembly.
Question Answered:
What are the key principles of DfM?
Simplify design, maintain consistent walls, design for cost and tolerances, and account for strength and assembly from the start.
The Can Art Perspective: Designing Smarter, Manufacturing Better
Great design starts with great collaboration, and that’s what we believe at Can Art Aluminum Extrusion.
We combine engineering insight, material science, and real-world extrusion experience to ensure every profile performs beautifully from concept to production.
We assist clients with:
- Material and alloy selection
- CAD design reviews and simulation
- Die design and prototyping
- Post-extrusion finishing and assembly optimisation
Whether it’s a complex architectural framework, a precision machine component, or an EV structure, our engineering team ensures that every aluminum profile meets the highest standards of quality, accuracy, and efficiency.
DfM Is About Making Designs Smarter, Not Just Easier
Design for Manufacturability (DfM) is more than making products easier to produce, it’s about making them better, smarter, and more economical.
By following these five fundamentals, you’ll create lightweight, durable, and cost-efficient aluminum extrusions ready for scalable production.
At Can Art Aluminum Extrusion, we turn smart design into flawless execution, so you can make the most of every millimeter of aluminum.
