Aluminum Extrusions: Custom & Standard Profiles for Every Industry
Bonnell Aluminum specializes in high-performance aluminum extrusions, offering custom and standard profiles for a wide range of industries, including construction, automotive, industrial equipment, and consumer durable products. With decades of expertise and state-of-the-art extrusion technology, we provide precision-engineered aluminum extrusions designed for durability, strength, and versatility.
- Preheating the Aluminum Billet – The raw aluminum is heated to a malleable state (typically 750–900°F).
- Extrusion Through a Custom Die – The heated aluminum is forced through a precision-machined die to create the desired cross-sectional profile.
- Cooling & Hardening – The extruded shape is rapidly cooled using water or air quenching.
- Stretching & Straightening – The profile is stretched to correct any distortions and ensure dimensional accuracy.
- Cutting to Length & Finishing – Extrusions are cut to customer specifications and may undergo finishing processes such as anodizing or machining.
To learn more about our extrusion capabilities, fill out this form and you will receive our capabilities brochure.
What is an Aluminum Extrusion?
Aluminum extrusion is a manufacturing process that transforms aluminum billets into specific shapes using a high-pressure extrusion press. The process involves:
This versatile process allows for the creation of complex shapes with superior strength-to-weight ratios, making aluminum extrusions ideal for lightweight, high-performance applications.
Bonnell Aluminum Extrusion Capabilities
Our advanced extrusion capabilities allow us to produce both standard and highly customized aluminum profiles.
Custom Aluminum Extrusions
Need a unique aluminum profile for your project? We specialize in custom-engineered extrusions tailored to your precise specifications. Whether you require intricate designs, high-strength properties, or lightweight solutions, our engineering team works with you from concept to production.
- Precision dies for complex shapes
- High-strength, lightweight aluminum alloys
- Tolerances that meet or exceed industry standards
- Value-added machining & fabrication options
Standard Aluminum Extrusions
We offer a wide range of standard aluminum extruded profiles, including:
- Aluminum angles, bars, and channels
- Hollow and solid aluminum tubes
- T-slotted extrusions for modular framing
- Structural and architectural profiles
Why Choose Bonnell Aluminum?
Industry-Leading Expertise
With over 70 years of experience in US aluminum extrusion manufacturing, we are trusted by top manufacturers for precision, quality, and reliability.
State-of-the-Art Extrusion Presses
Our advanced press technology allows us to extrude profiles with tight tolerances, complex geometries, and superior surface finishes.
- Press sizes ranging from 1,650 to 5,500 tons
- Profile sizes up to 20 inches in width
- Industry-leading tolerances & material consistency
Diverse Alloy Selection
We extrude aluminum profiles using high-performance alloys, including:
- 6063, 6061, 6005A, 6463, 6105, 6560, and 6320 aluminum for strength and corrosion resistance
- Specialty alloys for high-strength and high-heat applications
Comprehensive Finishing & Fabrication Services
Enhance the durability, appearance, and functionality of your extrusions with our in-house finishing and fabrication options:
- Anodizing – Improves corrosion resistance and aesthetic appeal
- Painting-Meeting AAMA 2603, 2604, and 2605 specifications.
- Machining & Cutting – Precision fabrication for ready-to-use components
- Thermal Break Technology – Essential for energy-efficient window and door systems
Industries & Applications
Our custom and standard aluminum extrusions serve diverse industries, including:
Construction & Architecture
- Curtain wall systems & Storefronts
- Commercial window and door frames
- Commercial canopies and walkway covers
- Sunshades and louvers, rain screens and water collection systems
- Structural aluminum profiles
- Metal floor and wall trim
Transportation & Automotive
- Lightweight vehicle components
- Crash Management systems
- Heavy Truck Front-End grills
- EV battery enclosures and charging stations
- High-strength chassis structures
Industrial & Manufacturing
- Framing and assembly lines
- Conveyor systems
- Machine guarding and enclosures
Consumer & Retail
- Custom furniture components
- Display and signage systems
- Home improvement products
Start Your Aluminum Extrusion Project Today
Whether you need custom-engineered aluminum extrusions or standard aluminum profiles, Bonnell Aluminum delivers exceptional quality, precision, and service from US manufactured aluminum.
To Request a Quote, please fill out the appropriate RFQ form below:
