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In many applications, aluminum extrusions can successfully replace steel components while offering several advantages.

Aluminum provides an excellent strength-to-weight ratio, meaning it can deliver structural performance while significantly reducing overall weight. This can improve efficiency in applications such as automotive, transportation, industrial equipment, and infrastructure systems.

Extrusion also allows engineers to integrate multiple design features—such as ribs, channels, and hollow sections—into a single profile. This can reduce part counts, simplify assembly, and lower overall manufacturing costs.

When evaluating a steel-to-aluminum conversion, factors such as load requirements, corrosion resistance, finishing needs, and fabrication processes should be considered. Our team works with customers during the design stage to help determine whether an aluminum extrusion is a suitable alternative for their application.

Minimum order quantities for aluminum extrusions depend on several factors, including the profile design, alloy selection, and the weight of the extrusion profile.

Depending on the profile size and weight, production may be scheduled on one of our extrusion presses. For many profiles, typical minimum order quantities range from approximately 500 kg to 1,000 kg.

During the quoting stage, our team reviews each project to determine the most efficient production quantities based on the specific requirements of the application.

Aluminum extrusions can be finished in a variety of ways to improve durability, corrosion resistance, and appearance.

Common finishing options include:

• Mill finish for applications where the natural aluminum surface is acceptable
• Anodizing for enhanced corrosion resistance and decorative finishes
• Powder coating for durable colored coatings
• Brushed or polished finishes for aesthetic applications

The appropriate finishing process depends on the application, environmental conditions, and performance requirements. Our team works with customers to determine the best finishing option for their extrusion profile.

Yes. In addition to aluminum extrusion, Dajcor offers a range of secondary operations to support complete component manufacturing.

These services may include precision machining, fabrication, cutting, drilling, and finishing processes such as anodizing or powder coating, depending on the requirements of the application.

Providing these value-added services allows customers to streamline their supply chain by sourcing fully finished components from a single manufacturing partner.

Dajcor Aluminum operates multiple extrusion presses, including two 9-inch 2800-ton presses, one 8-inch 2800-ton press, and one 7-inch 1650-ton press. These presses allow us to manufacture a wide range of aluminum profiles for structural, architectural, automotive, and industrial applications.

Our extrusion capabilities support profiles with a circumscribing circle diameter (CCD) of up to approximately 11 inches, with extrusion lengths of up to 28 feet, depending on the profile design and alloy.

During the design and quoting stage, our engineering team reviews each profile to confirm compatibility with our press capabilities and to ensure the extrusion can be manufactured efficiently while meeting dimensional and performance requirements.

Early collaboration helps optimize profile design for manufacturability, cost efficiency, and long-term production success.

Dajcor Aluminum primarily extrudes alloys from the 6000 series, which are widely used for structural and industrial applications due to their excellent strength, corrosion resistance, and machinability.

Common extrusion alloys include:

• 6063 – Widely used for architectural and general-purpose applications with excellent surface finish
• 6463 – An architectural alloy that provides enhanced surface finish and anodizing quality
• 6061 – A higher-strength alloy commonly used in structural and industrial components
• 6082 – A strong structural alloy often used where higher mechanical strength is required
• 6005 / 6005A – Suitable for structural applications requiring higher strength than 6063
• 6060 – An alloy commonly used for profiles requiring good extrudability and surface quality

Our team works closely with customers to select the most appropriate alloy based on the application’s strength requirements, finishing needs, and fabrication processes.

If your project requires a specific alloy or performance characteristic, our engineering team can help determine the best material for your extrusion profile.

Dajcor Aluminum supplies custom aluminum extrusions to a wide range of industries that require lightweight, durable, and high-performance components. Our extrusions are used in applications across sectors such as:

• Automotive and transportation
• Electric vehicle (EV) components and electrification infrastructure
• Defense and aerospace support applications
• Construction and architectural systems
• Industrial equipment and automation
• Renewable energy systems
• Lighting and electrical systems
• Consumer and commercial products

By working closely with engineers and manufacturers, Dajcor helps develop extrusion solutions that improve product performance, reduce component weight, and simplify manufacturing and assembly.

Aluminum extrusion tolerances depend on several factors, including the size and complexity of the profile, wall thickness, alloy selection, and the circumscribing circle diameter (CCD) of the extrusion. Industry standard tolerances are typically based on guidelines published by the Aluminum Association, which define achievable dimensional accuracy for solid, hollow, and semi-hollow profiles.

With Dajcor’s 7”, 8 “ and 9-inch extrusion presses, we are able to produce a wide range of aluminum profiles that meet standard Aluminum Association tolerances across many applications. During the design and quoting stage, our team reviews each profile to confirm achievable tolerances based on the specific geometry and manufacturing requirements.

Working collaboratively during the design phase helps ensure the extrusion profile is optimized for manufacturability while maintaining the dimensional precision required for the application.

To ensure an accurate quotation and efficient project evaluation, it is important to provide detailed information when submitting an aluminum extrusion RFQ.

Typical information includes:

• Profile drawings or CAD files showing the extrusion cross-section
• Circumscribing Circle Diameter (CCD) or overall profile dimensions
• Aluminum alloy requirements (such as 6061, 6063, etc.)
• Surface finishing requirements (anodizing, powder coating, mill finish, etc.)
• Fabrication or secondary operations such as machining, cutting, drilling, or assembly
• Estimated annual production volumes
• Target project timeline or production start date

Providing this information allows our team to evaluate tooling requirements, confirm manufacturability, and develop accurate pricing and lead times.

Early collaboration during the quoting stage also helps identify opportunities to optimize the extrusion design for manufacturing efficiency, cost reduction, and long-term production success.