Customization
We offer custom aluminum extrusion profiles, and we can combine extrusion with CNC milling, turning, and bending to make the final parts.
Low Volume Aluminum Extrusion Services
- Rapid Prototypes & Short Runs
- Custom Profiles, No Minimums
- Precision Finishing & Quality
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Aluminum Extrusion Services
High-volume extrusion companies are often unwilling to handle low-volume aluminum and plastic extrusion projects. At KIXENER, we have solid partners for short-run custom aluminum extrusions and prototype plastic extrusions. They take good care of our projects, both in quality and lead times. We also routinely do quality control on your project before shipment.
Our quality assurance process includes CMM inspection, surface finish verification to specified Ra values, and detailed documentation for full traceability. Every extrusion is straightened and inspected prior to post-machining.
Low Volume
Most extrusion companies set very high MOQs. KIXENER doesn’t. One-off prototype extrusions or a few hundred units? No problem.
Fast Delivery
If you don’t want to wait 30+ days for molds and profiles, come to us. We can finish everything in half the industry-standard time or even less.
Compared with traditional extrusion companies, we have a large amount of CNC machines, so we can do precision post-machining in house.
Custom Low Volume Extrusion Services
Plastic Extrusion
Plastic materials include polystyrene, nylon, polypropylene, and polythene. These thermoplastics are heated and pressured to form different shapes and sections.
Aluminum Extrusion
Aluminum is forced through a shaped opening in a die and emerges as an elongated piece with the same profile. Alloys we commonly work with include 6061 and 6063.
What is Aluminum Extrusion?
Aluminum extrusion is the process of shaping aluminum by forcing it to flow through a shaped opening in a die. The material comes out as an elongated piece with a continuous cross-sectional profile that can be highly complex. Think of how pasta shapes are made—except aluminum billets require huge hydraulic pressure and, in some cases, heat.
How Does Aluminum Extrusion Work?
Hot extrusion allows greater volumes at lower pressure, while cold extrusion can produce mechanically superior parts with a good surface finish. For hot extrusion, billets are heated to 300–600 °C, then a hydraulic ram forces them through the die at around 10,000,000 pounds of pressure. Extrusions are cooled, cut to length, and can be heat treated to harden the aluminum.
Aluminum Alloys for Extrusions
We work with Alloy 1100 for corrosion resistance, Alloy 2024 for high-strength aerospace, Alloy 6061 for general-purpose structural components, Alloy 6063 for architectural profiles, and Alloy 7075 for demanding high-stress applications.
Common Extrusion Applications
Aerospace
Lightweight structural profiles and precision-cut lengths.
Automotive
Crash structures, rails, and custom trim sections.
Construction
Rails, balustrades, ladders, and architectural frames.
Medical Devices
Clean, corrosion-resistant housings and supports.
Electronics
Heat sinks and enclosures with complex cross-sections.
Industrial Machinery
T-slot systems such as 2020 and 80/20 extrusions.
Our Low-Volume Extrusion Advantages
- Low MOQ for prototypes and short runs
- Custom dies and standard profiles
- In-house CNC post-machining, tapping, and threading
- Anodizing, powder coating, painting, and engraving
- CMM inspection before shipment
- Lead times in half the industry-standard window
Custom Aluminum Extrusion Profiles
Custom aluminum extrusion profiles can be cut to any 2D cross-sectional shape. Standard profiles include circular bar, square tube, 2020 (20 mm × 20 mm), and 80/20 T-slot aluminum extrusion.
Creating a custom extrusion, then using a CNC mill to add details, holes, or threads. Creating a round extrusion, then using a CNC lathe to add taper. Creating a custom extrusion, then adding text with a laser cutter.
Finishing Options for Aluminum Extrusions
Basic mechanical finishing
Buffing, bead blasting, and grinding can adjust surface quality, sometimes in preparation for other finishes.
Anodization
Improves corrosion resistance and appearance, including colored anodize for architectural and consumer parts.
Painting
Matte, gloss, or textured paint to alter color and surface appearance.
Powder coating
A suitable alternative to anodizing, giving excellent chemical resistance and consistency of tone.
Silk-screen printing
One of the simplest ways to add text and logos, cheaper than machine-based finishing procedures.
Laser engraving
Adds durable detail, including serial numbers, that will not rub off over time.
A customer’s words mean more than ours
See what our satisfied customers have said about how we fulfilled their requirements.
Thanks to KIXENER's 5-axis machining capabilities, we’re able to push the limits on our uprights and wheel package designs for maximum performance. Their bespoke and rapid manufacturing services allowed us to complete our project on time and ahead of schedule.
FSAE School of EngineeringMy prototype from KIXENER arrived earlier than expected with outstanding quality. Their manufacturing standards and machining precision are impressive. They provided excellent customer service and clear communication. Highly recommended.
Trent L.KIXENER delivered high-precision parts for our low-volume project with excellent lead time and competitive pricing. Communication with them was fast and helpful, and the team even provided useful design feedback. All parts worked perfectly.
Sivan S.KIXENER has been our top source for CNC parts. Even complex 5-axis CNC machining projects delivered excellent results. The team provides high-quality parts, fast production, anodizing and laser logo services, and reliable communication.
T. J.Aluminum & Plastic Extrusion FAQ
We specialize in low-volume aluminum extrusion. Dedicated extrusion companies may not accommodate small to medium-size orders or prototyping. Beyond extrusion, we also provide aluminum machining and casting for complex, integrated designs.
Our most commonly used alloys are 6061 and 6063, which contain high levels of magnesium and silicon. Both are highly corrosion resistant. You may specify a different alloy, and we will review feasibility when providing a quotation.
We have a selection of trusted extrusion partners who fulfill our orders, but KIXENER will do post-machining and check the parts before shipment.
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