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.
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:
- 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.
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:
