Custom Aluminum Extrusion Services
Alusat is an aluminum extrusion manufacturer based in Dongguan, Guangdong, China, supplying custom aluminum profiles to OEM customers across North America, Europe and Asia. As a single-source manufacturing partner, we take your drawing from the first extrusion die design through heat treatment, fabrication, machining, finishing and final inspection — all under one roof and one quality system.
When you need more than a catalog profile, Alusat delivers custom aluminum profile solutions — extruded shapes engineered around your drawing, tolerance and finish, then fabricated, machined and finished into parts that arrive installation-ready.
Extrusion Press Capability
Our plant runs a complete extrusion value chain so accountability for quality never leaves the building:
- Press tonnage — a range of extrusion presses covering small to large profile sections within a single facility.
- Profile geometry — solid, hollow, semi-hollow and multi-void shapes, including thin-wall sections for weight-sensitive designs.
- Wall thickness control — consistent, repeatable walls with die-line management for cosmetic and structural surfaces.
- Cut lengths — standard and custom cut lengths, deburred and packed to your specification.
Because every operation is co-located, a design change that would normally bounce between several suppliers is resolved in one conversation.
Alloy Range for Your Application
Alusat extrudes the full range of wrought aluminum alloys used in structural, thermal and cosmetic applications:
- 6061 — the general-purpose structural alloy, easy to machine and weld, ideal for frames and brackets.
- 6063 — the architectural and decorative alloy, with excellent anodizing response for visible surfaces.
- 6005A — a higher-strength structural alloy for transport and framing systems.
- 6082 — a strength-optimized alloy for demanding mechanical and structural parts.
- 7075 — the high-strength aerospace-grade alloy for performance-critical components.
Our engineers recommend the right alloy and temper for your load, thermal and cosmetic requirements, verify chemistry and temper before shipment, and document the result for traceability. Common tempers include T5 and T6 for structural parts and T4 where further forming is required after extrusion.
Extrusion Dies and Tooling
The die determines profile quality, so we invest in it up front. Alusat designs and manufactures solid, hollow and multi-void extrusion dies, choosing single- or multi-cavity layouts based on section size, wall thickness and annual volume. Die features such as bearing length and relief are tuned to control metal flow, reduce die lines and hold tolerances; for thin-wall or complex hollow sections this tuning is the difference between a profitable profile and a scrap-prone one. Standing tooling is stored, maintained and recertified between runs, so repeat orders start from a known-good die rather than a fresh setup.
Heat Treatment and Tolerances
Typical aluminum extrusion capabilities at Alusat include:
- Aging ovens for T4, T5 and T6 tempers to reach the mechanical properties your application demands.
- Dimensional tolerances to international standards, with tighter custom limits available where the application requires them.
- Straightness and twist controlled within standard extrusion limits, with corrective straightening where needed.
If your drawing calls for a tolerance tighter than standard, send it to us — we will tell you early whether it is achievable by extrusion alone or needs secondary CNC machining.
Industries We Serve
Alusat’s extruded aluminum components serve a wide set of industries:
- Automotive & EV — battery tray rails, enclosure sections, roof rails and structural members where mass reduction improves range and efficiency.
- Electronics — amplifier chassis, sensor housings, rack mounts and enclosures with integrated heatsink features.
- Heat sinks — extruded fin stacks for servo drives, power supplies, LED engines and telecom equipment.
- Solar energy — frame sections, rail channels and inverter housings resistant to outdoor corrosion.
- LED lighting — linear housing extrusions, track profiles and downlight rings with built-in thermal paths.
- Architecture — curtain-wall mullions, window and door frames, balustrade rails and decorative trims.
Engineering Support and Design for Manufacturability
Before any tooling is cut, Alusat’s engineers review your drawing for extrudability. We look at wall-thickness consistency, symmetry, die-line risk, tolerance achievability and how the profile will be handled and finished after extrusion. Where a small change in geometry removes a secondary operation or improves yield, we will tell you — because a profile that is cheap to make is cheap to buy.
Built for Global OEM Customers and Export Markets
Alusat supplies OEM manufacturers and brand owners who build products for export markets in the United States, the European Union and across Asia. We are accustomed to international documentation, packing and logistics — from first-article and PPAP-style submission packages to export crating and container consolidation — and we work in metric and imperial drawings alike.
Start Your Aluminum Extrusion Project
Whether you need a one-off prototype or a high-volume OEM program, Alusat can take your 2D or 3D drawing or sample and return a feasibility review, die plan and quotation. Use the quote form below to send your drawing, target alloy, quantities, tolerances and finishing requirements, or email our engineering team directly at hank@alusat.com.