Production route
We produce standard and custom aluminium profiles for the needs of different industries. From die design to extrusion and from surface treatment to shipping, we handle every stage of production according to the technical requirements of the product.
We plan the right production process by assessing the technical drawing, the application and the order requirements together. We work towards dimensional accuracy, surface quality and consistency in repeat orders.
Not every profile goes through every process. Anodising and electrostatic powder coating are alternative surface options. Whether machining and punching are done before or after coating, and whether taping and individual wrapping are needed, is planned according to the product’s technical requirements.
The dimensional accuracy, function and production consistency of an aluminium profile start with a correctly designed die. Alongside standard profile requirements, we also assess custom section requests based on our customers’ technical drawings and intended use.
The profile’s outer dimensions, wall thicknesses, hollows and connection details are reviewed together with the system it will be used in. Narrow channels, thin walls and differences in thickness within the section are assessed for manufacturability. The requested tolerances and surface requirements are agreed at this stage.
The die geometry is designed so that the aluminium flows evenly across the section. The structure of the section, the selected alloy and the extrusion conditions are assessed together in the design, and the effect of later surface treatments on fit and connection dimensions is also taken into account.
Profile samples taken from trial production are compared with the technical drawing. Critical dimensions, wall thickness distribution, straightness and surface appearance are assessed, and die corrections and process adjustments are made where necessary.
Wear and build-up that occur during use can affect the profile’s dimensions. Cleaning, inspection and maintenance of dies are part of production continuity, and section and revision details are kept for repeat orders.
Extrusion is the main production stage in which aluminium is turned into the designed section. The billet, heated to the appropriate temperature, is pushed through the die under press pressure and takes the form of the profile. Our aim is to produce profiles to the specified dimensions with properties suitable for repeat production.
The alloy is selected by assessing the expected mechanical properties, the surface treatments and the service environment together. Before production starts, the profile section, the requested lengths, the quantity and the subsequent operations are taken into account.
During extrusion, temperature, exit speed and material flow directly affect the profile’s geometry and surface quality. Process conditions are set to support even formation of the thin and thick areas of the section.
Profiles leaving the press are cooled under the conditions required by the alloy and the target mechanical properties. Stretching and straightening are used to remove geometric deviations such as bow and twist.
Profiles are cut to the lengths specified in the order. In heat-treatable alloys, mechanical properties are improved by ageing. After length, section, straightness and surface checks, the profiles move on to the next stage.
Machining prepares the extruded profile to the dimensions and details of its end use. Length and angle cuts, connection details and other machining requests are planned from the technical drawing. Models that need serial punching on the flanges are routed to the eccentric press line.
The areas to be machined, reference dimensions and tolerances are agreed before production. For products that need more than one operation, the sequence is set by taking into account how the dimensions relate to one another.
Cuts are planned according to the length and angle requirements in the technical drawing. Supporting the part properly, especially with thin-walled and open sections, helps reduce dimensional deviation and deformation.
Mounting and connection details are assessed according to the section and its purpose. Products that need a regular hole pattern on the flanges are processed separately on the eccentric press line with a suitable die.
The machining sequence is set according to the surface finish and the conditions of end use. Finished parts are checked for length, hole positions, cut faces and overall form.
We punch holes and openings that suit the product’s use in the flanges of flanged aluminium profiles. The profile is fed in a controlled way and punched with a punch and die set that suits the section.
The flange width, wall thickness and required hole shape are assessed together. The die and settings are chosen according to the geometry of the profile.
The shape, position and pitch of the holes are planned for each model. Feed and alignment settings aim for a regular hole pattern along the profile.
The profile is guided with suitable guides and supports during the process. The feed is checked so that the flanges are not crushed or bent and the profile stays straight.
At the end, the size, position and edges of the holes are checked. Any deburring is completed and the profile is prepared for the next stage.
Anodising is an electrochemical process that forms a controlled oxide layer on the aluminium surface. This layer is integral to the metal itself and, under suitable conditions, increases corrosion and wear resistance while keeping the metallic appearance of the aluminium.
Before anodising, the profile surface goes through cleaning and pre-treatment stages. Because anodising leaves the surface character of the underlying metal visible, the initial surface quality of the profile determines the final appearance.
The properties of the oxide layer are set according to the product’s conditions of use. Coating thickness, surface requirements and the technical function of the part are assessed together, and the effect of the coating on dimensions in fit and connection areas is taken into account.
Natural or coloured anodising options are considered in line with the required appearance and technical suitability. Because the alloy, surface preparation and process conditions can affect the final shade, the colour requirement is agreed on a sample.
The pores in the oxide layer are closed by sealing in line with the process plan. In the final inspection, appearance, colour match and coating properties are assessed, and the profiles are prepared for the next stage in packaging that protects their surfaces.
Electrostatic powder coating is a coating method that gives aluminium profiles colour and surface texture. The powder particles are applied to the surface electrostatically and cured under suitable oven conditions to form the coating layer.
Colour options are assessed according to RAL references and project requirements. In addition to the colour code, the gloss level, surface texture and whether the product will be used indoors or outdoors are also agreed.
Removing oil, dirt and unsuitable residues from the surface is the basis of powder coating. After pre-treatment the profiles are rinsed and dried. This preparation supports coating adhesion and performance.
The powder adheres to the surface through electrostatic charge, and the corners, channels and recesses of the section are assessed for coating distribution. The profiles are cured at the temperature and for the time required by the powder’s technical specification.
Coated profiles are assessed for appearance, colour, gloss and coating uniformity. In fit and assembly areas, the effect of coating thickness on functional dimensions is taken into account, and colour, texture and gloss details are kept for repeat orders.
Depending on their use, we prepare profiles with a protective surface film or an adhesive tape that helps installation. The tape type, width and the surface it goes on are chosen according to the profile’s finish and use.
A film is applied to help protect the decorative surface against abrasion during transport, storage and installation. Its adhesion and peel properties are chosen to suit the profile’s finish.
On models designed for taped mounting, adhesive or double-sided tape is applied to the relevant surface. The choice depends on the profile’s finish, the surface it will be bonded to and the application conditions.
The application surface is kept clean and dry. As the profile moves between the guides, rollers press the tape evenly onto the surface along the set line.
The tape width, position and contact are checked. Wrinkles, overhang at the edges and loose areas are assessed, and the profile is prepared for packing.
Each profile passes through the machine on its own and is wrapped in film. Wrapping profiles individually helps reduce direct contact with other parts during storage and transport.
Every part, including small sections, is fed into the machine separately. Infeed and outfeed supports keep the profile moving smoothly and straight.
Film and machine settings are assessed according to the profile’s section, length and surface. The aim is an even wrap around each single profile.
The wrap is checked for integrity, slack or tears, and the ends are inspected. The need for extra protection at points that may be sensitive in transport is assessed.
Individually wrapped profiles are counted and grouped by order. Once outer packing and labelling are complete, they are arranged for shipping.
Packaging and dispatch are planned so that the product properties achieved in production are preserved until the goods reach the customer. The length, section structure and surface finish of the profiles are important in deciding on suitable packaging.
Products are compared with the order for profile type, length, colour, surface treatment and quantity. In shipments containing different products, items are grouped to reduce the risk of mix-ups.
The protective material and packing arrangement are chosen according to the profile’s surface properties. For anodised and powder-coated surfaces, the compatibility of the packaging material with the finish is important.
The weight, length and handling method of the packs are considered together. Products are labelled using order details such as profile code, length, colour and quantity.
Dispatch is planned according to the delivery address, the transport method and when the order will be ready. Requests for part deliveries or special packaging are agreed during order planning.
We treat quality as part of every stage of production, from reviewing the technical drawing to preparing shipments. Dimensional accuracy, the expected surface and fitness for use are our priorities in the first order and in repeat production.
Section dimensions, wall thickness, length, straightness and surface appearance are assessed for each product. On coated products the colour and surface are checked; on machined parts the holes, connections and post-machining shape. On taped and wrapped products, the quality of application is inspected too.
Not every profile goes through the same processes. Anodising and powder coating are alternative surface options for most products. Whether machining and punching are done before or after coating, and whether taping and individual wrapping are needed, is planned according to the product’s technical requirements.
Share your technical drawing, the application, the length and quantity you need and, if any, your alloy and surface expectations. Let us plan the die, machining, surface treatment and delivery together according to your order.
A standard profile or a custom section: we will assess your request with you.
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