Aluminum Extrusion Services
From prototype profiles to production runs, KaiSpeed delivers custom extrusions with fast tooling, engineer-led DFM, CNC post-machining, bending/forming, and production finishes—ready to assemble.
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What Is Aluminum Extrusion?
Aluminum extrusion forms metal by forcing a heated aluminum billet through a precision die—the metal flows and emerges as a continuous length with the die’s cross-section. Change the die, change the profile. Think of squeezing Play-Doh through a shaped nozzle—same idea, engineered for high strength and accuracy.
How the process works:
Billet prep: Cut and heat a 6xxx-series aluminum billet to the proper temperature.
Extrusion: A hydraulic ram pushes the billet through a hardened steel die (direct or indirect extrusion).
Quench & straighten: The profile is water/air quenched, then stretched to remove twist and bow.
Age/temper: Controlled aging to reach the specified temper (e.g., T5/T6/T66).
Cut & finish: Cut to length, then CNC machine, drill/tap, slot, bend/stretch-form, and apply the required finish.
Our Aluminum Extrusion Services
If you need very high volumes of a simple profile cut to length, a mass-production extruder may be the most economical route. But when you need prototypes, short runs, or engineering support, large mills often won’t take the job—or won’t move fast enough.
KaiSpeed fills that gap. We work with a vetted network of extrusion partners optimized for low-to-mid volumes, while our in-house team handles DFM, CNC post-machining, finishing, and QC so your parts arrive ready to assemble. We also support select plastic extrusions for programs that need both metal and polymer profiles.
Low MOQ & short runs: prototypes, pilot builds, and small batches—no VIP status required
Fast tooling & samples: rapid die kick-off with clear timelines
In-house precision: extensive CNC milling/turning, drilling/tapping, slotting, and forming/bending
Quality you can audit: dimensional checks, cosmetic reviews, CoC/material certs on request
Low Volume
Most mills set high MOQs. KaiSpeed doesn’t. Whether you need a one-off prototype extrusion or a few hundred pieces, we’ll quote, build the die, run, and finish—so you can validate design, fit/function, and cosmetics before scaling.
Customization
We build custom aluminum profiles to your drawing, then combine extrusion with CNC machining, turning, bending/stretch forming, welding, inserts, and light assembly to deliver finished parts. Finishes include anodize (Type II/III), powder coat, electrophoresis, chromate conversion, bead-blast/brush/polish, and laser/pad print.
Fast Delivery
Don’t wait a month (or more) for first articles. Our streamlined die design + partner press capacity + in-house post-ops compress the schedule from DFM → die → first samples → finished parts. Share your CAD, alloy/temper, finish, and volumes—we’ll return a clear plan and target dates.
Applications of Extrusion
Extrusion is the most efficient way to create continuous, complex cross-sections with excellent straightness, repeatability, and finish—ideal for long lengths, thin walls, and parts that need secondary CNC features and surface treatments. KaiSpeed supplies prototype runs through production for a wide range of industries.
Architecture & Construction
Window/door frames, trims, mullions, curtain wall systems
Handrails, balustrades, ladders, scaffolding
Structural angles, channels, tubes ready for anodize or powder coat
Electronics & Thermal Management
Heat sinks & heat-spreader profiles (high fin density, consistent thermal paths)
Enclosures/chassis, cable raceways, connector housings
EMI-/IP-ready designs with machining for ports, threads, and gasket lands
Aerospace, UAV & Transportation
Aircraft/airframe members, seat tracks, stiffeners
Automotive/EV battery trays, roof rails, interior/exterior trims
UAV chassis arms, gimbal housings—lightweight with high stiffness-to-weight
Industrial Machinery & Automation
Conveyor frames, guarding, machine bases
T-slot framing systems, linear guides, racks
Complex thin-walled enclosures with post-machined CTQs
Lighting, Consumer & Appliances
Linear fixture bodies, bezels, bezels with optics slots
Appliance trims, handles, decorative profiles
Furniture/retail systems with brushed/anodized finishes
Marine & Outdoor
Masts, rails, decks, housings using corrosion-resistant alloys/finishes
24/7 Support • Fast Global Delivery • Secure NDA Protection
How to Work With Us
01. Share CAD & requirements
Send STEP + PDF with alloy/temper, finish, target lengths/volumes, CTQs/GD&T and any compliance. NDA welcome.
02. DFM & quote
Engineer-led DFM: die concept (solid/semi-hollow/hollow), wall/draft/radii review, tongue/bridge feasibility, parting/cosmetics plan, finish stack, and a schedule to first articles—plus pricing.
03. Tooling & samples
Build die → trial run with photos → dimensional summary (FAI/CMM) and cosmetic assessment; iterate as needed until approval.
04. Production & delivery
Extrude → heat treat/age (T5/T6) → straighten → CNC/trim/bend → finish (anodize/powder/e-coat/chromate) → QC report → pack & ship with CoC/material certs.
Aluminum & Plastic Extrusion — FAQs
We’re optimized for low–to–mid volumes and fast iteration. Many large extruders prefer long runs; we handle DFM → die build → extrusion → CNC post-machining → finishing → QC and ship parts ready to assemble.
Yes. Common choices are 6063 (excellent surface/anodize, thin walls) and 6061 (higher strength). Both are Al-Mg-Si alloys (magnesium + silicon). We also run 6005A/6082/6463 and others. Tell us your load, finish, and cost targets—we’ll confirm feasibility at quote.
Yes—prototype lengths and small batches are available. We can also CNC-machine or 3D-print a proof-of-concept before committing to a custom die.
Alloy & temper
Profile size/weight per meter
Die complexity (solid vs. semi-hollow vs. hollow; tongue ratio)
Tolerances & inspection level
Volume & cut lengths (long bars vs. cut-to-size)
Post-machining, forming, and finishes (anodize, powder, e-coat)
Send your drawing/spec and we’ll quote with clear line items.
Keep uniform wall thickness; use ribs/gussets vs. heavy masses.
Prefer generous radii and symmetry; avoid deep, narrow slots.
Use standard alloys (6063/6061) and standard tolerances where possible.
Consolidate operations and avoid late design changes once the die is built.
Discuss DFM early—catching tongue/bridge and cooling issues upfront saves time and money.
Solid dies: no internal voids (simplest, most economical).
Semi-hollow dies: partially enclosed features/slots.
Hollow dies: fully enclosed voids/tubes, using mandrels/bridges (most complex).
Common metric “series” include 20/30/40/45/50/60/80/100/160 mm (e.g., 2020, 2040, 3030, 4040, 4545, 4080, 8080). Slot widths (e.g., 6/8/10 mm) and nut styles vary by vendor—share your ecosystem or we’ll match hardware compatibility.
Typical materials include PVC (rigid/flexible), ABS, PC, PMMA (acrylic), PE (LDPE/HDPE), PP, TPU/TPE, PA (nylon), and blends. We’ll advise on UV stabilizers, flame ratings, and FDA/ROHS needs.
Masterbatch colors, co-extrusion (caps), matte/gloss textures, and printing/embossing are available. For clear optics, PC/PMMA with polishing/post-finishes can be specified.
Plastics move with temperature/humidity; expect looser as-extruded ranges than aluminum. We’ll set profile-specific tolerances and control critical features with fixtures and downstream machining if required.