Not all aluminum profile designs are extrusion-friendly.
Ignoring extrusion limits leads to increased tooling cost and inconsistent quality.
Core Engineering Logic
Extrusion complexity is constrained by:
- Wall thickness variation
- Internal cavities
- Die strength and material flow
Designers must align profile ambition with manufacturing reality.
Practical Engineering Considerations
- Maintain uniform wall thickness
- Minimize deep internal voids
- Consider post-machining instead of over-complex extrusion
Advanced Material Perspective
Hybrid material concepts often introduce additional processing steps that reduce scalability.
Extrusion-aware design improves cost predictability and production stability.