Custom Aluminum Extrusion Profiles
HTS-ALU specializes in custom aluminum profiles for industrial and architectural applications, including aluminum profiles for windows and curtain wall systems, industrial structures, decorative trims, and photovoltaic (PV) mounting systems.
What We Can Customize
HTS-ALU manufactures custom aluminum extrusions from customer drawings or samples. We can customize profile shape, alloy and temper, dimensions and tolerances, surface finish, machining, assembly, and packaging for industrial and architectural applications.
- Custom aluminum extrusion manufacturer
- From drawings to finished components
- Extrusion + machining + surface finishing
- Fast tooling & lead time support
Custom Profile Shapes and Structures
We can manufacture solid, hollow, and semi-hollow aluminum profiles in simple or complex cross-sectional shapes. Each profile is developed according to its geometry, wall thickness, strength requirements, installation method, and intended application.
Hollow Aluminum Profiles
Produced using porthole extrusion dies for complex hollow structures and internal cavities. Commonly used for window and door systems, industrial frames, furniture profiles, and lightweight structural applications.
Solid Aluminum Profiles
Suitable for high-strength industrial components and machined structural parts. In addition to extrusion control, uniform heat treatment and deformation control are important for maintaining mechanical performance and dimensional stability.
Multi-Cavity Aluminum Profiles
Designed for complex architectural and industrial systems with multiple internal chambers. These profiles require advanced die design and specialized extrusion production methods to ensure stable wall thickness and profile precision.
Thin-Wall Aluminum Extrusions
Suitable for lightweight applications and precision industrial products. The extrusion limit can reach 0.6 mm wall thickness, while cold drawing processes can further achieve approximately 0.3 mm thin-wall structures.
Large-Size Aluminum Extrusions
Large structural profiles require high-tonnage extrusion presses for stable production. HTS-ALU operates extrusion presses up to 6000 tons, supporting maximum profile diagonal dimensions up to 406 mm.
Seamless Aluminum Extrusions
Produced using reverse extrusion technology for improved structural integrity and sealing performance. Commonly used for tubes, pressure-resistant systems, and high-performance industrial applications.
Custom Extrusions for Your Application
Custom aluminum extrusions can be developed for window and curtain wall systems, industrial equipment, furniture, decorative trims, solar mounting systems, transportation, and other project-specific applications. We adjust the profile design and production method to suit its function and operating environment.
Surface Finishes and Color Options
We can customize the surface finish and color according to appearance, corrosion resistance, wear resistance, and outdoor performance requirements. Available options include anodizing, powder coating, electrophoresis, PVDF coating, wood grain transfer, sandblasting, and brushed finishes.
Anodizing
An electrochemical oxidation process forming a protective oxide layer on the aluminum surface. In addition to standard anodizing, hard anodizing is also available for applications requiring higher surface hardness and wear resistance.
- Oxide Film: AA10 / AA15 / AA20
- Surface: Matte / Satin / Smooth
- Colors: Silver / Black / Bronze / Champagne
- Features: Corrosion resistance, wear resistance, metallic appearance
Electrophoretic Coating
Electrophoretic coating is applied on top of the anodized layer to provide a smoother surface, improved weather resistance, and enhanced coating durability.
- Surface: Matte / Gloss / Smooth
- Colors: Silver / Champagne / Bronze / Black
- Features: Uniform coating, enhanced corrosion resistance, smooth appearance
Powder Coating
Powder coating provides durable decorative finishes with excellent weather resistance and flexible color customization for aluminum extrusion profiles.
- Coating Thickness: 40–120 μm
- Colors: Custom RAL Colors Available
- Surface: Glossy / Semi-Gloss / Matte / Textured
- Features: Wide color selection, UV resistance, durable finish
PVDF Coating
High-performance fluorocarbon coating designed for demanding outdoor architectural and industrial applications. PVDF coating offers better long-term weather resistance and color stability compared with standard powder coating.
- Coating Thickness: 30–65 μm
- Surface: Metallic / Smooth / Architectural
- Features: Excellent UV resistance, outdoor durability, long-term color retention
Wood Grain Transfer
Heat transfer printing technology creating realistic wood textures on aluminum profiles while maintaining aluminum’s structural strength and corrosion resistance.
- Texture Options: Wood Grain / Marble Grain
- Surface Style: Natural Wood Appearance
- Features: Wood-like appearance, decorative finish, low maintenance
Sandblasting
Surface treatment using abrasive blasting to create textured metallic surfaces before anodizing or decorative finishing. Different sandblasting particle sizes can be selected according to visual and surface texture requirements.
- Surface: Fine Matte / Textured
- Appearance: Industrial / Decorative
- Features: Premium texture, uniform surface effect, customizable sandblasting roughness
Machining, Fabrication and Assembly
Custom profiles can be supplied as extruded lengths or finished components. Available services include precision cutting, CNC machining, drilling, tapping, punching, slotting, bending, welding, and component assembly according to customer drawings.
Punching
Punching, involves applying high force to create holes, indentations, or other shapes in aluminum profiles. This process is essential for creating ventilation openings, mounting slots, or lightweight structures with uniform patterns.
Drilling
Drilling creates necessary holes in aluminum profiles, allowing for the attachment of components with bolts or other fasteners, crucial for modular constructions.
Cutting
Precision cutting is crucial to ensure that each aluminum profile is trimmed to exact length specifications, facilitating a perfect fit in final assembly.
Milling
Milling involves the removal of aluminum material using rotary cutters to achieve desired shapes and surfaces. This process is perfect for creating slots, grooves, and complex contours, enhancing the functionality and precision of aluminum profiles.
Tapping
Tapping adds threads to the drilled holes in aluminum profiles, enabling the secure fastening of bolts and screws, which is vital for assembly and maintenance.
Bending
This technique shapes aluminum profiles into desired curves or angles, maintaining material integrity and is essential for both architectural and functional structures.
CNC Machining
Utilizing computer-controlled machinery, this process allows for precise and complex geometrical cuts on aluminum profiles, ideal for custom specifications.
Welding
Welding joins multiple aluminum sections into a solid unit, providing a durable bond essential for structural applications.
Assemble
Our assembly services involve the strategic joining of various components using bolts and other fasteners to create complex assemblies, ensuring functionality and structural integrity.
Custom Aluminum Extrusion Options
HTS-ALU provides flexible specification options for custom aluminum extrusion projects, allowing profiles to be optimized for structural performance, appearance, and downstream processing requirements.
| Item | Specification |
|---|---|
| Alloy Series | 1000 Series / 3000 Series / 5000 Series / 6005 / 6060 / 6061 / 6063 / 6082 |
| Heat Treatment | T5 / T6 / T66 |
| Maximum Width | ≤ 406 mm |
| Maximum Length | ≤ 12 m |
| Wall Thickness | ≥ 0.8 mm |
| Surface Finish | Anodizing / Electrophoresis / Powder Coating / PVDF / Wood Grain / Sandblasting / Brushed Finish |
| Fabrication Services | Precision Cutting / Drilling / Tapping / Milling / Punching / Welding |
| Tooling Development | 7 Days for New Tooling / Sample Testing Available / Tooling Cost Refund for Volume Orders |
Custom Extrusion Production Capabilities
Our production capabilities cover die development, aluminum extrusion, heat treatment, surface finishing, precision machining, inspection, assembly, and export packaging. This allows us to manage custom extrusion projects from the initial drawing to finished components.
Our extrusion facility operates over 40 aluminum extrusion lines, including large-capacity forward and reverse extrusion presses, with a maximum press capacity of up to 6000 tons.
This enables us to produce custom aluminum profiles in a wide range of sizes and structural designs, including hollow, solid, thin-wall, large-size, seamless, and thermal break aluminum profiles. Our extrusion capability supports both small-batch development and large-scale production for industrial and construction applications.
HTS-ALU provides in-house mold design and development services for custom aluminum extrusion profiles, ensuring optimal extrusion feasibility and dimensional accuracy.
Different profile structures require different die types, including solid dies, hollow dies, and porthole (bridge) dies. Our engineering team designs extrusion tooling based on profile geometry, wall thickness, alloy selection, and application requirements.
By controlling the entire mold development process internally, we are able to shorten tooling lead times, improve extrusion stability, and support both prototype development and mass production for custom aluminum extrusion projects.
We offer a complete range of in-house surface treatment options for aluminum profiles to meet different corrosion resistance, appearance, and application requirements.
Available surface finishes include anodizing, electrophoretic coating, powder coating, PVDF coating, and wood-grain transfer printing. Surface treatment processes are selected based on profile application, environmental conditions, and aesthetic specifications.
Integrated surface finishing ensures consistent color control, stable coating quality, and efficient production scheduling for both architectural and industrial aluminum profiles.
HTS-ALU provides comprehensive machining and fabrication services after aluminum extrusion, delivering ready-to-install aluminum components.
Our post-fabrication capabilities include CNC machining, cutting, drilling, punching, bending, welding, assembly, laser marking, and logo silk-screen printing. These services allow aluminum profiles to be processed according to exact project and installation requirements.
By combining extrusion, machining, and assembly under one roof, we help customers reduce supplier coordination, improve dimensional consistency, and shorten overall project lead times.
Our Aluminum Extrusion Factory
Our factory operates more than 40 extrusion lines together with in-house tooling, heat treatment, surface finishing, and machining facilities. This integrated production setup supports aluminum profiles with different sizes, structures, finishes, and processing requirements.
Why Choose HTS-ALU for Custom Extrusions
HTS-ALU is a professional custom aluminum extrusion manufacturer in China, with over 20 years of experience supporting architectural and industrial projects worldwide.
• Custom aluminum extrusion and in-house tooling based on customer drawings or samples, supporting both standard and non-standard aluminum profiles.
• Extensive die resources and fast tooling response to meet urgent project schedules and development timelines.
• 40 advanced extrusion lines, including large-capacity forward and reverse extrusion presses, enabling both small-batch and large-volume production.
• Complete in-house surface finishing and precision machining services, delivering true one-stop aluminum extrusion solutions.
• Fast and reliable lead times, with typical tooling completed in 7–10 days and standard production within 15–20 days, depending on order quantity.
How We Customize Your Aluminum Extrusion
At HTS Aluminum Profiles, we specialize in delivering custom aluminum extrusion solutions tailored to your specific needs. Here’s a step-by-step guide to our customization process:
1. Drawing Analysis
We accept CAD drawings, STEP files, PDF drawings, and reference images. Sample-based profile measurement and drawing development are also available for custom aluminum extrusion projects.
2. Tooling Development
Tooling drawings will be provided for customer confirmation before mold production. New extrusion dies are typically completed within 7 days, followed by trial extrusion and sample approval before mass production.
3. Extrusion & Heat Treatment
Custom aluminum profiles are produced through extrusion and heat treatment processes including T5, T6, and T66. Production time for one full container (approximately 26 tons) is usually around 1 week.
4. CNC Machining & Fabrication
Precision cutting, drilling, punching, milling, tapping, and welding services are available. STEP drawings and machining tolerance requirements are recommended for custom fabrication projects.
5. Surface Finishing
Available surface finishes include anodizing, electrophoresis, powder coating, PVDF coating, wood grain transfer, sandblasting, and brushed finishes. For custom colors, customers can provide color samples or standard RAL color codes.
6. Packaging & Shipment
Protective packaging, pallet packaging, labeling, and export shipment services are available according to customer requirements. Custom logo marking on aluminum profiles is also supported.
Custom Aluminum Profile Project Case
For custom aluminum profile projects, customers are requested to provide technical drawings or physical samples for evaluation. If post-fabrication or precision machining is required, STEP format (3D) electronic drawings are strongly recommended to ensure accurate manufacturing. Customers should also confirm the aluminum alloy and heat treatment condition, surface finishing requirements, and packaging specifications in advance.
Case 1 - Hospital Building Aluminum Profile
Aluminum Alloy: 6063-T5; 6061-T6
Surface Finish：clear anodizing ; hard anodizing for outdoor use.
Machining: drill; CNC; assembled
For this large-scale hospital construction project, HTS-ALU developed more than 30 custom extrusion dies to support different architectural aluminum profile requirements. Aluminum profiles used for interior applications were treated with clear anodizing to achieve a clean appearance and corrosion resistance, while profiles for outdoor use received hard anodizing for enhanced surface hardness and durability. Most profiles required drilling and machining, and selected components were pre-assembled into complete kits before delivery, helping the customer reduce on-site installation time. Thanks to fast production and flexible coordination, HTS-ALU fully supported the project construction schedule and ensured timely delivery at each stage.
Case 2 - Aluminum Cable Ladder System
Aluminum Alloy: 6063-T5; 6061-T6
Surface Finish：mill finish
Machining: punch; welding
In this industrial cable management project, HTS-ALU worked closely with the customer to develop custom extrusion dies for both side rails and rungs based on technical drawings. The aluminum profiles were produced with T6 heat treatment, achieving a hardness level of approximately 16 HB, meeting the project’s mechanical strength requirements. Both side rails and rungs were punched using dedicated stamping dies to ensure consistent hole positioning and high production efficiency. According to customer requirements, the cable ladder components were welded and assembled before delivery. In addition, HTS-ALU designed and manufactured a complete range of custom connection accessories, providing the customer with a true one-stop aluminum cable ladder solution, from extrusion and machining to assembly and final delivery.
Request a Quote for Custom Aluminum Extrusions
To provide an accurate quotation and ensure efficient production, please confirm the following information:
Technical drawings or samples
Electronic drawings in DWG or STEP (3D) format are preferred.Material specification
Aluminum alloy grade and heat treatment condition.Surface finishing requirements
Such as anodizing, powder coating, electrophoretic coating, PVDF coating, or others.Packaging requirements
Including protective packaging, bundling, pallets, or customized export packaging.
Minimum wall thickness: from 0.6 mm, depending on profile design and alloy
Maximum profile size: up to 500 mm diagonal envelope, subject to extrusion feasibility
Final dimensions are confirmed after engineering evaluation.
The minimum order quantity varies depending on profile size, alloy, and processing requirements:
Typical MOQ ranges from 500 kg to 2000 kg per profile
For orders below the standard MOQ, production is still possible with a small additional material loss or handling cost
The total cost of custom aluminum profiles is calculated based on the following components:
Aluminum raw material cost
Extrusion processing cost
Heat treatment
Surface finishing
Machining and fabrication (if required)
Packaging and handling
Each quotation is calculated according to the specific project requirements.
Tooling fees vary depending on profile size, structure, and die type
In some cases, tooling fees can be refunded after reaching a specified purchase quantity
Example:
For a standard T-slot 4040 aluminum profile, the mold fee is approximately USD 200.
The tooling cost can be refunded after a total purchase volume of 1 metric ton.
