Designing aluminum extrusion forms is a serious job, regardless of the sort of job you perform or the purpose of the aluminum extrusion forms your organization employs. There are a lot of factors to consider when working with widths ranging from.100′′ to tremendously enormous spans built from various sorts of aluminum alloys. When dealing with the design of bespoke aluminum extrusions, there are a lot of fundamentals to consider, but there are also certain specific factors that designers may employ to get some fairly fantastic outcomes. Can You Extrude 7075 Aluminum? 1. Alloy When it comes to developing aluminum extrusion forms, the type of aluminum alloy you employ is crucial. There are various options available, but some are used more frequently than others because to intrinsic features like as strength, simplicity of usage, surface polish, and other factors. The following are some of the most regularly utilized aluminum alloys in the custom aluminum extrusions industry: 7075 - The most mechanically strong of the four alloys most commonly employed in the creation of aluminum extrusion parts. Because of their strength, these aluminum alloys are commonly utilized in airplane structural components. 6061 — This alloy has a considerable amount of mechanical strength. It has excellent machineability and is utilized in a wide range of industrial applications. 6063 – The mechanical strength of aluminum alloys in this group is poor. Structural trim, doors, and windows are among the most common uses. 3003 – The mechanical strength of this substance is quite low. It is acceptable for heat transfer applications, however it is not suited for structural applications in any form. 2. Temper The temper of aluminum alloys is another factor to consider when selecting materials for making aluminum extrusion forms. Here's a rundown of the tempers connected with the four most prevalent alloys we mentioned before, as well as why they might or might not be preferred over other possibilities. 7075 — This aluminum alloy is difficult to extrude and has a poor surface quality. 6061 – This material is also more difficult to extrude than the other two aluminum alloys we'll be talking about, but it has a finer finish than 7075. 6063 — These aluminum alloys are easier to extrude than 6061, with which it shares certain similarities, and have a high-quality surface finish. 3003 – This material is the easiest to extrude of all the aluminum alloys mentioned here, and it has an excellent surface polish. 3. Thickness The consistency and regularity of the thickness of the walls within the aluminum extrusion forms is one area in which many manufacturers ignore when constructing aluminum extrusion. Because the aluminum alloys flow through the die at a more consistent pace, shapes with uniform thickness will be the easiest to manufacture. Because the aluminum is driven through the largest regions the fastest, while moving slowly through the narrower regions, dies with uneven wall thicknesses can be difficult to manufacture properly. If the thinner pieces do not fill properly, the entire item built from bespoke aluminum extrusions may be compromised and twist during production. In order to avoid the potentially detrimental impacts connected with wall thickness fluctuations, it is necessary to work with a professional and skilled service provider, such as Silver City Aluminum. 4. Tolerances The rule of thumb to remember is that the greater the size of the form you're trying to make, the greater the tolerance range that's necessary. For example, it is simpler to maintain a +/-.003′′ tolerance on the diameter of a.500′′ OD tube than it is on a 1.000′′ OD tube. Check out the Aluminum Standards and Data report, which is produced by the Aluminum Association, for additional information on the industry standard for tolerances. The book covers the construction of both conventional and bespoke aluminum extrusions, which may be used for both forms and tubes.