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Extrusion Design Dilemmas

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Extrusion Design Dilemmas

Q. What are some of the important design factors to consider with mating extrusions?

Length of engagement of mating parts.
Provide sufficient clearance based on end finish, satin finish will etch .001/.002 off a surface and painting will add .003/.004 per surface
Keep in mind that a solid feature will start off small from tool build and an open area such as a socket will be built to the top side of tolerance to allow for die wear.
Use 2/3 of Aluminum Association tolerance to the top band of your limit on the female portion and 2/3 to the minus on the male component, ensuring min. and max. limits of parts do not create an interference fit or dis-engaging fit.
Try and use a consistent wall thickness and consider any stresses that may be applied to joint

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About The Expert

Ian Colquhoun
Ian Colquhoun has over 30 years of experience in the aluminum extrusion industry, designing complex aluminum profiles for the automotive, transportation, renewable energy, construction and renovation markets.

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Design versatility is a key component in the successful application of aluminum extrusions in various markets such as marine, medical architecture, military, transportation and OEM/Aftermarket automotive. The utilization of various finishing processes such as color anodizing, painting, mechanical brushing and buffing provide excellent aesthetic features for interior and exterior applications.

For industries that manufacture products in and for the shower/tub enclosure, curtain wall, construction, renovation and building sectors, aluminum extrusion and the secondary finishing processes such as anodizing and painting combine to provide durable, high quality products that the construction and renovation markets demand.

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