Custom Dies from Orange Aluminum


Aluminum extrusions have revolutionized the manufacturing industry by offering a versatile and cost-effective method for shaping aluminum into intricate profiles and components. Central to the process is the use of custom dies, which enable precise and customized extrusions to meet the unique requirements of various applications. In this article, we will explore the fascinating world of aluminum extrusions using Orange Aluminum's custom dies, shedding light on the process, benefits, and the multitude of industries that rely on this advanced manufacturing technique.

The Art of Aluminum Extrusion

Aluminum extrusion is a manufacturing process that involves forcing aluminum alloy through a die, resulting in the creation of specific cross-sectional profiles. The key element of this process is the die itself, which functions as a mold, determining the final shape and dimensions of the extruded aluminum product. Our custom dies take this process to the next level, offering unparalleled precision and flexibility.

Custom Dies: Precision in Every Detail

  1. Tailored Design: Our custom dies are meticulously designed to meet the exact specifications of the desired extruded product. We work closely with our clients to understand their requirements, whether it be a simple L-shaped profile or a complex, multi-chambered component. The customization allows for the creation of extrusions with tight tolerances and intricate geometries that off-the-shelf dies cannot achieve.
  2. Optimized Efficiency: Our custom dies are designed with efficiency in mind. They minimize material wastage by producing extrusions that closely match the required dimensions, reducing the need for extensive machining or additional processing.
  3. Versatility: Our custom dies can be adapted for various alloys, allowing manufacturers to choose the material that best suits the application, whether it's lightweight, high strength 6061 aluminum or a lightweight, corrosion-resistant 6063 aluminum.

The Process of Aluminum Extrusion Using Our Custom Dies

  1. Die Fabrication: The process begins with the creation of the custom die. Our engineers use computer-aided design (CAD) software to design the die, specifying every detail of the desired extrusion. The design is then translated into a physical die using precision machining techniques, often involving CNC machines for utmost accuracy.
  2. Heating and Extrusion: Aluminum billets are heated to a precise temperature, making them malleable. The billet is then loaded into the extrusion press, where it is forced through our custom die at high pressure. As the aluminum passes through the die, it takes on the exact shape of the die's profile.
  3. Cooling and Cutting: The newly extruded aluminum is rapidly cooled to maintain its structural integrity. After cooling, it is cut to the desired length, creating individual extrusions.

Applications of Custom Aluminum Extrusions

The versatility of our custom aluminum extrusions ensures their applications span across a wide range of industries:

  1. Construction: Custom extrusions are used extensively in the construction industry for window frames, curtain walls, structural components, and modular systems. Their lightweight yet sturdy nature makes them an ideal choice for building materials.
  2. Transportation: From aerospace components to automotive frames, aluminum extrusions find their way into various modes of transportation. The high strength-to-weight ratio of aluminum makes it an essential material for reducing fuel consumption and enhancing performance.
  3. Electronics: Extruded aluminum heat sinks are commonly used in electronic devices to dissipate heat generated by components, ensuring optimal performance and longevity.
  4. Consumer Goods: The sleek appearance and corrosion resistance of our custom aluminum extrusions make them a popular choice for consumer products such as furniture, sporting equipment, and appliances.


Aluminum extrusions using our custom dies represent the pinnacle of precision and efficiency in the manufacturing industry. With our ability to create tailored profiles and components, our custom dies enable manufacturers to meet the unique needs of diverse applications across various sectors. As technology continues to advance and industries demand increasingly complex and customized solutions, the role of custom aluminum extrusions and our meticulously crafted dies will only grow in importance, shaping the products and innovations of the future. If you're looking to harness the benefits of custom aluminum extrusions and are in need of custom dies, don't hesitate to reach out to us at (877) 464-2181. Our team of experts is ready to assist you in bringing your unique aluminum extrusion projects to life, offering solutions that are precision-crafted and optimized for your needs.

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