Custom Metal Extrusion Services
BaoSheng offers custom extrusion solutions for aluminum, copper, and steel, supported by engineering consultation, die design, production, and integrated secondary processing.
- Custom & standard extrusion profiles
- Aluminum, copper, and steel materials
- Tight tolerances & repeatable quality
- Integrated extrusion + CNC machining + finishing
STEP | STP | IGS | IGES | PRT | SLDPRT | SAT | X_T | PDF | CAD | & JPG With Product Detailed Size
Maximum file size: ≤15MB. Max. Files
All Uploads Are Secure And Confidential.
Trusted
What Is Metal Extrusion?
Metal extrusion is a forming process in which a metal billet is forced through a precision die to produce a component with a uniform cross-section. Near-net-shape production reduces material waste and enables high repeatability for volume production.
Benefits
Long, consistent profiles
Excellent strength-to-weight ratio
Compatible with secondary machining
High-volume repeatability
How Metal Extrusion Works
Billet Preparation – Metal billets are prepared and heated (hot extrusion) or conditioned (cold extrusion).
Die Design & Tooling – Precision dies shape the material and control flow.
Extrusion Press Operation – Billets are forced through the die.
Quenching & Straightening – Profiles are cooled and straightened.
Cutting & Inspection – Profiles are cut to length and inspected.
Secondary Operations – CNC machining, finishing, or assembly if required.
Extrusion Methods & Profile Types
Extrusion Methods
Hot Extrusion – Aluminum, copper, steel; complex profiles
Cold Extrusion – High dimensional accuracy
Impact Extrusion – Thin-wall and hollow components
Profile Types
Solid and semi-hollow
Hollow and multi-void
Thin-wall and asymmetric geometries
Custom engineered profiles
Upload your drawings or specifications to receive professional manufacturability feedback and a competitive quotation.
Materials We Support
Choosing the right metal is essential for extrusion performance. BaoSheng offers aluminum, copper, and steel alloys with expert guidance to ensure durability, manufacturability, and optimal results.
Copper & Brass
High electrical and thermal conductivity
Busbars, power and thermal components
Aluminum
6061, 6063, 6082, 7075
Used in structural frames, heat sinks, enclosures
Steel & Stainless Steel
High-strength, wear-resistant profiles
Industrial and structural applications
Extruded Aluminum Alloys Comparison Table
| Alloy | Description | Key Characteristics | Suitable Applications |
|---|---|---|---|
| 6061 | Versatile heat-treatable alloy with magnesium and silicon | High strength & toughness (40,000 PSI yield); excellent corrosion & fatigue resistance; weldable | Automotive and marine structural components |
| 6063 | Economical heat-treatable alloy with fine grain structure | Easily extruded; good corrosion resistance; responds well to finishing; ideal for thin-wall parts; moderate strength (20,000 PSI yield) | Decorative trim, heat sinks, architectural profiles |
Available Extruded Part Finishes
BaoSheng simplifies adding finishing to your metal extrusions. Through our network of suppliers, we provide both functional and cosmetic finishes for your parts.
As-Extruded
Parts are left in their original extruded state. Surface roughness typically ranges from 64–125µin Ra depending on alloy; visible grain lines or streaks may appear.
Anodized (Type II Or Type III)
Type II: corrosion-resistant oxide finish, available in clear, black, red, or gold.
Type III: thicker, wear-resistant coating in addition to corrosion protection. Non-conductive.
Powder Coating
Electrostatic application of powder followed by baking. Creates a durable, wear- and corrosion-resistant finish with various colors and textures.
Wet Painting
Traditional paint application in various formulations and colors. Color matching can be specified in drawings.
Plating
Options include nickel, brass, tin, chrome, chromate, silver, gold, or Teflon coatings for functional or aesthetic purposes.
Chemical Film
Chromate conversion coating protects aluminum from corrosion and improves paint adhesion while maintaining electrical conductivity.
Media Tumbled
Vibratory tumbling smooths edges and surfaces, suitable for small parts.
Custom
If your required finish isn’t listed, BaoSheng can explore additional options to meet your specifications.
Applications of Metal Extrusion
BaoSheng’s metal extrusion services are used to produce durable, high-precision components with continuous, complex cross-sections. Extruded parts are widely applied across industries where structural integrity, manufacturability, and cost-efficiency are essential.
Typical Applications Include:
Aircraft and automotive structural components
Window and door frames, architectural trim
Electrical connector housings and enclosures
Conveyors, ladders, and scaffolding
Complex thin-walled assemblies
Heat sinks and thermal management components
Extrusion enables the efficient production of parts that are difficult or impossible to create with other manufacturing methods, making it ideal for both standardized and custom components.
Metal Extrusion Advantages and Disadvantages
Advantages
Dimensional Accuracy & Stability
Modern extrusion processes produce consistent, close-tolerance profiles suitable for both brittle and ductile metals.Cost Efficiency
High-volume production of extruded frames and housings reduces part and assembly costs compared with multi-piece constructions.Lower Tooling Costs
Extrusion dies are simpler and less expensive than tooling for processes like die casting or injection molding.Complex Cross-Sections
Supports intricate profiles including T-slots, grooves, and other functional features.
Considerations
Initial Setup Costs
Die design and tooling represent upfront investment beyond the piece cost.Design Limitations
Extrusion profiles must maintain a constant cross-section. Features like countersinks, pockets, or bosses require secondary machining.Lead Times
Die production and extrusion setup can take several weeks, impacting initial delivery timelines.
FAQs
What is metal extrusion best for?
Long, constant cross-section parts like frames, rails, heat sinks.
Is extrusion cheaper than CNC machining?
For uniform profiles, extrusion reduces material waste and unit cost.
What affects tooling cost?
Profile complexity, wall thickness, material, and tolerances.