Custom Extruded Aluminum Case

HTS New Materials, based in Jiangxi Province, China, is a leading aluminum extrusion manufacturer with over 40 advanced production lines and powerful equipment, including a 6000-ton extrusion press. We produce a wide range of aluminum profiles for industries such as construction, industrial applications, and high-end doors and windows, including thermal break profiles. Our services extend to comprehensive surface treatments like anodizing, powder coating, fluorocarbon coating, and wood grain transfer, as well as advanced machining and fabrication capabilities such as CNC machining, drilling, and welding. Committed to quality and innovation, we deliver tailored aluminum solutions to meet the diverse needs of clients globally.

Selecting the right material for extruded aluminum cases is crucial to ensure the desired balance of performance, durability, and functionality. Different applications demand different material properties, and aluminum alloys provide versatility to match these requirements. Key considerations for material selection include:

1. Strength and Structural Integrity

For applications requiring high strength and load-bearing capacity, alloys such as 6061or 6005 are ideal choices. These alloys are durable, offering excellent mechanical properties suitable for structural components and industrial use.

2. Corrosion Resistance

If the case needs to withstand harsh or humid environments, alloys like 6063 or 6082offer superior corrosion resistance. These materials are especially suitable for outdoor, marine, and architectural applications.

3. Precision and Machinability

When precise machining or intricate profiles are required, alloys like 6061 and 6063perform exceptionally well due to their excellent machinability. These alloys allow for complex designs and tight tolerances, making them ideal for cases requiring high precision.

4. Surface Finishing Requirements

Aluminum cases often require surface treatments for enhanced aesthetics and durability. Alloys like 6063 are commonly used for anodizing due to their smooth surface and ability to produce a premium finish. Powder coating and other finishing treatments also adhere well to this material.

5. Lightweight with High Strength

For cases used in industries like aerospace or automotive, where weight reduction is critical, alloys such as 7075 or 6082 offer an exceptional strength-to-weight ratio. These alloys are designed to handle high-performance applications without adding unnecessary mass.

6. Cost Efficiency

For cost-conscious projects, alloys from the 6000 series—such as 6063 and 6005—strike the perfect balance between affordability, performance, and versatility. These materials are readily available and easy to process, reducing production costs without sacrificing quality.

Commonly Used Alloys for Extruded Aluminum Cases

• 6061: Strong, corrosion-resistant, versatile; perfect for structural designs.
• 6063: Lightweight, smooth surface, and ideal for intricate profiles and decorative finishes.
• 6005: Offers excellent strength with great corrosion resistance for demanding applications.
• 6082: Combines strength and corrosion resistance, suitable for heavy-duty or marine applications.
• 7075: Known for extreme strength and lightweight properties, used in aerospace and performance-focused industries.

By selecting the right aluminum alloy for your extruded case, you ensure that it meets the specific demands of your application, whether it involves durability, light weight, corrosion resistance, or cost efficiency. At HTS NEW MATERIALS, we guide you through the material selection process, helping you choose the best alloy to deliver high-performance extruded aluminum cases tailored to your needs.

1. Anodized Colors

Anodizing is a popular finish for aluminum cases, offering durability, corrosion resistance, and vibrant colors. Common anodized colors include:

• Silver/Natural Aluminum: Classic and polished finish, ideal for a modern, sleek look.
• Black: A professional and versatile color that is suitable for various industries.
• Gold: A premium look often used for luxury products.
• Champagne: A subtle, elegant tone for a sophisticated appearance.
• Bronze/Dark Brown: Adds warmth and a luxurious touch to the case.
• Custom Colors: Unique shades can also be achieved, such as red, blue, green, or pink, depending on your branding or product requirements.

2. Powder Coating Colors

Powder coating allows for a nearly limitless range of colors with a durable and even finish. These colors provide a thicker film coating compared to anodizing and are available in:

• Glossy, Matte, or Satin Finishes: Choose the finish that best suits your project’s style.
• Bright and Vibrant Colors: Such as red, yellow, green, or orange, for eye-catching designs.
• Neutral or Corporate Colors: Like white, grey, or black for minimalistic or branding purposes.

3. Polished and Brushed Finishes

If you prefer to enhance the natural metallic look of aluminum, polished or brushed surface treatments can be combined with clear or tinted coatings to add depth and elegance to the case. These can be left in their natural tone or lightly tinted with colors for a subtle effect.

4. Custom Branding Colors

For products requiring unique corporate branding, custom-matched colors are available through painting, anodizing, or powder coating. These options allow for brand-specific colors to be accurately reproduced, maintaining a consistent product identity.

5. Two-Tone or Multi-Color Designs

Advanced finishing techniques make it possible to incorporate multiple colors on one case to highlight specific areas or functions. This is especially useful for stylish or technical products where contrasting colors improve design or usability.

Selection Tips

Depending on your application, you can choose colors based on functional or aesthetic priorities:

• For durability and long-term use, anodized finishes are the best option.
• For vivid and customized designs, powder coating offers more flexibility.
• For a refined and professional look, polished or brushed finishes are excellent choices.

We provide a wide range of machining services for aluminum extrusions to meet specific requirements. These include cutting off/section removal, slotting, drilling holes, tapping threads, bending, and localized stamping to create deformations. For example, we can trim extruded profiles to custom lengths, mill precise grooves, create threaded holes for fasteners, bend profiles into specific shapes, or apply localized stamping to achieve custom forms or deformation.

In addition to these processes, we also offer TIG/MIG welding to join aluminum components for a solid structure. Furthermore, our services include assembly of common accessories, such as brackets, corner connectors, screws, hinges, end caps, and rubber seals, providing complete and ready-to-install profile solutions tailored to your project needs. This ensures that we can handle everything from simple cuts to highly customized fabrication and assembly, all with precision and efficiency.

For custom aluminum extrusion projects, we accept a variety of drawing formats, including CAD files, STEP files, and PDF files. However, for extrusions that require additional machining processes, it’s recommended to provide STEP files, as they ensure precise 3D modeling for machining accuracy.

While PDF files are acceptable, converting them into CAD drawings may result in the loss of certain details, requiring us to manually redraw the design, which could increase lead time. For the fastest and most accurate quotation, we recommend providing CAD files (e.g., DWG/DXF) and STEP files to ensure efficient design evaluation and pricing.

Mold fees are an essential part of the custom aluminum extrusion process. Since every order requires a uniquely designed mold tailored to specific requirements, these molds cannot be used for other products. Therefore, the mold fee is necessary and non-negotiable.

We require 100% upfront payment of the mold fee before mold development begins to ensure timely production. However, as a token of appreciation for your support, we offer a refund of the mold fee or equivalent discounts once the order reaches a certain production volume. Specific policies can be discussed based on your order volume and collaboration details.

Our minimum order quantity (MOQ) varies depending on the size of the product. For smaller-sized products, the MOQ is typically 500kg, while for larger-sized products, it is 2 tons.

We will specify the exact MOQ requirements during the quotation process. If your order quantity does not meet the MOQ, we can still arrange production, but an additional fee will be applied to cover mold preheating and production setup time. Rest assured, this extra fee will be reasonable, and we aim to keep it as minimal as possible to ensure smooth cooperation.

Packaging can be customized according to your needs. Options include using protective film or paper to separate and protect the surface, or foam film for additional surface protection. Products can be palletized or packed into cartons, and the quantity per pallet or carton can be specified by the customer.

The standard packaging involves bundling several pieces together with plastic wrap and then securing them onto pallets. Any packaging requirements beyond the standard will be accommodated, and the associated costs will be clearly provided to the customer.

Mold production typically takes 7 days. After the sample is confirmed, producing a full container load of 26 tons generally requires 14 days for extrusion alone. If surface treatment is required, an additional 3 days will be needed. For machining, extra time will be required depending on the complexity and volume of the machining work. The exact additional time for machining will be determined based on the specific processing requirements.

Aluminum profiles are naturally corrosion-resistant due to the formation of a thin, protective oxide layer when exposed to air or water. This oxide layer is stable and self-repairing, meaning that even if the surface is scratched or cut (such as at exposed ends or during processing), the aluminum will not rust or corrode like iron or steel. Instead, the exposed areas will quickly form a new oxide layer, providing continuous protection against further oxidation.

With proper design, installation, and maintenance, aluminum profiles can last for decades, even in challenging environments. For example, untreated aluminum can easily withstand 20-30 years in outdoor applications, while profiles with surface treatments like anodizing or powder coating can last even longer, often exceeding 50 years. This makes aluminum an excellent choice for applications where durability and long-term performance are essential.

The price of aluminum profiles consists of several components: raw material costs, extrusion processing fees, surface treatment fees, machining costs, and additional packaging fees. Among these, the cost of aluminum as a raw material tends to fluctuate frequently, while other fees remain relatively stable. Due to these fluctuations, our quotations are typically valid for 7 days.

Pricing can be structured in different ways depending on the product and requirements. It can be calculated by weight (e.g., cost per ton), by length (e.g., cost per meter), or by piece (e.g., cost per unit). For products involving extensive machining, such as heat sinks, pricing is generally calculated on a per-piece basis to accurately reflect the additional processing costs. This flexible pricing approach ensures the quote is tailored to the specific needs of the customer.

We can manufacture aluminum profiles in compliance with technical requirements that meet European standards (EN), American standards (ASTM/AA), or other standards as specified by the customer. Custom production is tailored to ensure that the profiles meet the specific standard requirements requested.

Our production equipment is designed for the metric system. If the drawings provided are in the imperial system, we will convert them into metric units for production to ensure accuracy.

It is important to note that while we can machine imperial-threaded holes for fasteners, if you require us to supply matching imperial fasteners, they may not always be available in stock. Custom orders for imperial fasteners typically require a large volume for production. Please consider this when planning your project.