5 Key Aluminum Manufacturing Processes Enable Custom Solutions

From lightweight aerospace components to sleek smartphone casings, aluminum is ubiquitous in modern manufacturing. Its machinability, corrosion resistance, and versatility make it a material of choice. But transforming raw aluminum into precision-engineered products requires specialized techniques. Here, we explore five core aluminum processing methods to help you balance performance, aesthetics, and cost-effectiveness.

1. CNC Machining: Precision for complex geometries
2. Aluminum Extrusion: Efficiency for uniform cross-sections
3. Sheet Metal Fabrication: Speed for flat and bent components
4. Aluminum Casting: Economies of scale for high-volume production
5. Aluminum Forging: Superior strength for critical applications

CNC (Computer Numerical Control) machining uses automated cutting tools to sculpt intricate parts from solid aluminum blocks or extruded profiles. This subtractive manufacturing process achieves exceptional tolerances (typically ±0.01mm or better), making it ideal for prototypes and small-to-medium production runs.

• Exceptional dimensional accuracy and repeatability
• Capability to produce complex geometries
• Superior surface finishes (enhanceable via anodizing or polishing)
• Compatibility with various alloys (e.g., 6061-T6, 7075-T6)

• Higher material waste compared to additive methods
• Diminishing cost-effectiveness at high volumes
• Suboptimal for simple, mass-produced components

Prototypes, enclosures, mechanical components, electronic parts, and low-volume production.

This process forces heated aluminum billets through dies to create continuous profiles with uniform cross-sections. Extruded components are typically cut to length and may undergo secondary machining for mounting features.

• Excellent material utilization (minimal waste)
• Cost-effective for long, uniform profiles
• Rapid production scaling
• Good mechanical properties (especially 6000-series alloys)

• Restricted to constant cross-sections
• Initial die investment required
• Often requires secondary operations

Structural frames, rails, LED housings, heat sinks, handles, and brackets.

Combining cutting (laser, punch), bending, and joining techniques, sheet metal fabrication transforms flat aluminum stock into functional parts. This method excels in producing enclosures, panels, and brackets with quick turnaround times.

• Rapid production cycles
• Cost-effective for medium-to-high volumes
• Broad material thickness options
• Suitable for functional and decorative applications

• Limited capacity for complex 3D shapes
• Potential strength limitations (may require reinforcements)
• Surface finish challenges if improperly handled

Enclosures, mounting brackets, control panels, cabinets, and electronic housings.

Casting involves pouring molten aluminum into molds (die casting, sand casting, investment casting) to create near-net-shape parts. This method dominates automotive and appliance manufacturing for high-volume components.

• Capable of intricate geometries
• Low per-unit cost at scale
• Integration of multiple features into single parts
• Compatible with post-processing (machining, finishing)

• High tooling costs (especially for die casting)
• Lower mechanical properties versus wrought alloys
• Potential surface porosity requiring additional finishing

Engine components, housings, appliance parts, and decorative items.

Forging uses compressive forces to shape aluminum under extreme pressure, aligning grain structures for enhanced strength. This method is preferred in aerospace and automotive applications where reliability is paramount.

• Exceptional strength and impact resistance
• Minimal internal defects
• Ideal for subsequent machining/heat treatment
• Consistent quality in mass production

• Significant tooling investment
• Geometric complexity restrictions
• Impractical for prototyping/low volumes

Suspension arms, aerospace components, high-stress brackets, and structural supports.

Choosing the optimal aluminum processing method requires evaluating:

• Geometric complexity: CNC for intricate designs; casting for organic shapes
• Production volume: Sheet metal for medium batches; casting for mass production
• Tolerance requirements: CNC for tight tolerances; casting for general precision
• Mechanical properties: Forging for maximum strength; extrusion for balanced performance
• Budget constraints: Sheet metal for cost-sensitive projects; CNC for premium precision

Different alloys suit specific processes:

• CNC: 6061-T6 (general purpose), 7075-T6 (high strength)
• Extrusion: 6063/6060 (excellent extrudability), 6061 (stronger alternative)
• Casting: A380/ADC12 (die casting), AlSi10Mg (investment casting)
• Sheet Metal: 5052-H32 (formability), 6061-T6 (structural applications)
• Forging: 2014, 7075 (aerospace-grade strength)