Editor’s Note: This blog post (originally published in June 2021) has been updated for accuracy and comprehensiveness.
Everyone knows the classic scenario. You have a great idea for a project, but figuring out what material to use is daunting. And if you don't get it right at first, you have to figure out how to overcome design and assembly nightmares later. Thankfully, aluminum extrusion lets you build anything with simplicity and efficiency.
With its high strength-to-weight ratio, corrosion resistance, and versatility, aluminum extrusion is a top choice for the design, engineering, and assembly of your projects. This step-by-step guide will show you how to get the most out of this versatile material to help you build your project with sustainability in mind.
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How to Build Anything with Aluminum Extrusion | What is Aluminum Extrusion? | Why Use Aluminum Extrusion? | Three-Step Process | Accessories | Maintenance and Longevity | Frequently Asked Questions | Additional Resources
Key Takeaways Aluminum extrusion provides versatile customization options through T-slots, enhancing design flexibility and assembly efficiency. Aluminum’s lightweight, strength-to-weight ratio, and corrosion resistance make it a cost-effective and durable choice for projects. Using design software and consulting with experts can significantly optimize aluminum extrusion projects, ensuring tailored solutions and effective planning. |
In this video, we walk through how to build anything with this modular material from start (designing & allocating materials) to finish (assembling the final project). Watch the video on YouTube or keep reading to learn more.
This method allows for the production of various shapes, including solid, hollow, and semi-hollow forms, which can be tailored to meet specific design needs. The resulting extrusions typically feature a central hole and one or more T-slots, making them incredibly versatile and easy to work with.
When we talk about aluminum extrusion in this article, we'll be focusing on T-slot profiled aluminum extrusion.
T-slot aluminum extrusions are the most commonly used in industrial manufacturing, which makes the pieces interchangeable with strong slotted connections that screw together. The unique T-shaped slots allow for easy integration of various components and accessories, allowing lots of customization and reuse. This design makes it possible to bolt rather than weld parts together, allowing for quick assembly, disassembly, and reconfiguration as project needs evolve.
It's a fair question - but an easily answered one. Aluminum extrusion has four main benefits that make it one of the easiest materials to work with.
1. Strong, Clean, and Modern Aesthetic: The industrial look is in, and aluminum profiles can be made as strong as necessary for each design while staying lightweight. They are also corrosion-resistant, making it viable in different environments and climates, and can even be rated for clean rooms.
2. Easy to Assemble and Disassemble: Putting the framework together takes minutes and is as simple as inserting connectors into the T-slot and tightening, all using basic hand tools. The connections are strong but non-permanent, so no welding is needed. Join the materials at any place, any time, and save the giant construction mess for somebody else.
3. Aluminum Extrusion is Versatile and Modifiable: There are many profiles, shapes, and sizes that all work with the t-slot design framework, along with an extensive library of handles, casters, plates, brackets, gussets, and more.
These components can fit together in any way you choose, both large architectural projects and small custom projects. Also, because the framing connections are modular, projects can easily be taken apart and customized to fit the next one, all without wasting material.
Say you've built a workstation that is a bit too tall. The fix is as simple as loosening some screws, adjusting the height, and re-tightening. Extra holes can also be drilled for further customization.
4. A Cost-Effective Solution. Custom profiles help save money by reducing the need for extra welding or joining, while aluminum’s lightweight properties make handling and shipping more affordable. Whether you’re working with small or large order sizes, extrusion is a budget-friendly method for producing parts. Plus, purchasing surplus lengths of aluminum extrusions allows you to cut them to your exact needs, making it an economical option for many projects.
Designing with aluminum extrusions opens up a world of possibilities. These components can be customized to meet precise functional needs, making them perfect for lots of different projects. Whether you need hole drilling, thread tapping, miter cutting, or milling, custom machining ensures your extrusions are tailored to fit seamlessly into your design—boosting both efficiency and accuracy.
But before diving into machining, though, the first step is perfecting your design with the right software. Some engineers may prefer their go-to programs, especially for large or complex projects. However, if you're looking for a user-friendly option, we recommend Rexroth’s MTpro or MTpro Light. With its 3D layout designer, MTpro allows you to virtually assemble your framing project and generate CAD models if needed. It also offers detailed product information—everything from framing profiles and finishes to lengths and accessories—making the design and ordering process effortless.
Software is downloadable on Rexroth’s Website:
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Airline Hydraulics team of engineers have been working with this material for years and know how to get the most out of it. Contact us with your design questions; they'd be happy to help bring your ideas to life. |
Now that you nailed your design (I knew you could do it), it's time to prepare materials for aluminum framing; there are several options to consider. Aluminum extrusion can be bought in a few different ways, but how you choose to buy it really comes down to your capabilities to cut and machine your materials.
Aluminum extrusions can be purchased in unmodified lengths or as pre-finished framing material, depending on your needs.
If you have the proper equipment to cut, drill, and machine aluminum extrusion, you can order unmodified aluminum extrusion in its full length, either as a bundle or by the stick in its original length without end finishing. Then you can supply your team with a list of lengths and machine end finishes to fabricate your perfect project solution yourself.
If you don't have a shop where you can cut and fabricate material lengths, holes, and end finishes, you have Airline provide materials that are already finished. Just choose your extrusion, cut its length to millimeters or inches, and choose machine end finishes. These machine-end finishes include custom hole drilling, thread tapping, miter cutting, milling, and more.
You can even request a kit option, What's a kit? Our experienced engineers will work with you to realize a design for your build. Once finalized, we'll send you a ready-to-build aluminum extrusion kit with everything you need to build it. With all the extrusion profiles, connectors, and accessories pre-machined, cut-to-length, and organized, you won't have to worry about any extra fabrication work or guesswork. Check out our YouTube video to see how easy it is to assemble anything using our DIY, ready-to-build aluminum extrusion kits.
Components can be connected using T nuts, square nuts, and preset nuts, allowing for secure and flexible accessory attachment. Corner brackets and 3-way corner connectors further simplify the assembly process, enhancing structural integrity and ease of use.
Also, it's great for easy reconfiguration and makes reusing materials simpler and more cost-effective than ever. What's even nicer is if you bought a kit, the worksite is so clean and efficient with everything ready to assemble. Basic hand tools can bolt everything together, so say goodbye to harsh welding and disruptive project sites.
Accessories can significantly enhance the functionality and aesthetics of your aluminum extrusions. Cover plates, feet, casters, wheels, doors, handles, and hinges are just some of the accessories available to customize your build. These components add extra strength and utility, making your aluminum frame more versatile and user-friendly.
3D printing can also be utilized to create custom brackets and accessories, further enhancing the adaptability and customization of your aluminum extrusions. This technology allows for the creation of unique and specialized components that perfectly fit your design needs.
Airline can design and ship projects across North America and offers extra accessories like lighting, sensors, conveyors, and customized shelving. We want to help bring your projects to life.
Aluminum structures are known for their longevity and low maintenance needs. Unlike other metals like steel, aluminum does not rust or decay like wood, contributing to its long lifespan. The natural resistance to corrosion enhances the durability of T-slot frames in various environments.
With proper design and assembly, aluminum frames can maintain structural integrity under substantial loads, making them a reliable choice for long-term use.
If you need help with any of these steps to build anything, Airline Hydraulics Corporation is able to assist with or fully complete the design, material prep, and installation. Please don’t hesitate to ask your local Airline Representative. New to Airline? Contact us for assistance with ordering or customizing an order; one of our customer service representatives will get you in touch with one of our experts.
Frequently Asked QuestionsWhat are the main benefits of using aluminum extrusions in projects?
Using aluminum extrusions in projects provides high strength-to-weight ratios, excellent corrosion resistance, and recyclability while also being cost-effective. These benefits make aluminum extrusions an ideal choice for a range of industry applications. How does T-slot aluminum extrusion enhance the versatility of projects?
T-slot aluminum extrusions significantly enhance project versatility by enabling easy integration of components, facilitating quick assembly and disassembly, and offering extensive customization options. This adaptability allows for efficient modifications as project requirements change. What tools are essential for assembling aluminum structures?
Essential tools for assembling aluminum structures include Allen wrenches, cutting and drilling tools, and hole tapping tools. These are crucial for ensuring precise and secure assembly. Where can I purchase aluminum extrusions?
You can purchase aluminum extrusions from suppliers like Airline Hydraulics Corporation with a cost-effective option being to buy surplus lengths and cut them yourself. How do aluminum structures compare in terms of maintenance and longevity?
Aluminum structures are highly durable and require minimal maintenance due to their resistance to rust and warping. This makes them a reliable option for long-term applications. |
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