Custom Aluminum Extrusion Fabrication Services
Alusat turns extruded aluminum profiles into finished, inspection-ready components. Beyond the extrusion itself, we provide precision cutting, drilling, tapping, bending, welding and assembly, so you receive a part that is ready to install rather than a raw length of profile that still needs work.
For procurement and engineering teams, fabrication is where an aluminum profile becomes a functional part. By keeping every operation under one roof, Alusat eliminates hand-offs between suppliers and keeps lead times short and results consistent.
Fabrication Capability
Our fabrication cell handles the operations most specified for extruded aluminum:
- Precision cutting — mitre, notch and square cuts to length with clean edges and tight repeatability.
- Drilling and tapping — hole patterns, threads and cross-holes located to drawing.
- Bending — controlled bend angles and radii for brackets, frames and enclosures.
- Welding — TIG and MIG welding of aluminum sections into sub-assemblies.
- Assembly — fastening, insertion and build-to-print assembly of multi-part modules.
From Profile to Finished Component
A typical fabrication program at Alusat follows a predictable path:
- Review and fixturing — we examine the drawing for bend allowance, weld access and hole placement, then build or program the fixtures.
- Cutting — profiles are cut to length and notched as required.
- Drilling and tapping — holes and threads are produced to the pattern.
- Bending — sections are formed to the specified angles and radii.
- Welding — joints are made and checked for penetration and appearance.
- Assembly and inspection — parts are assembled, inspected and prepared for finishing or packing.
Because fabrication sits next to extrusion and machining, we iterate quickly when a design changes.
Tolerances and Quality Control
Fabricated features are held to your specification:
- Cut-length and angle tolerances verified against the drawing.
- Hole pattern accuracy confirmed with fixtures and gauges.
- Weld quality checked for penetration and appearance.
- Traceability maintained with documented build records per order.
We apply disciplined in-process checks and final inspection so that a fabricated module arrives consistent with the approved sample.
Design for Manufacturability
Our engineering team reviews every fabrication inquiry for bend radii, weld access, hole placement and fixturing, and proposes changes that reduce cost or rework before production starts. A small change in geometry can remove a secondary operation or improve yield — and we will tell you when that is the case.
Combined with Machining and Finishing
Because extrusion, fabrication, CNC machining and surface finishing share one site, a profile can move from cut blank to finished, coated component without leaving our facility. This vertical integration is what lets us quote realistically, hold lead times and keep tolerances consistent from first prototype to high-volume production.
Industries Served
- Automotive & EV — fabricated rails, brackets and structural members.
- Industrial automation — T-slot frames, guard enclosures and cable-management channels.
- Electronics — enclosures and housings with integrated features.
- Architecture — window, door and curtain-wall fabricated sections.
- Solar energy — frame and rail assemblies resistant to outdoor corrosion.
Start Your Fabrication Project
Send your drawings, quantities, material grade, tolerances and finishing requirements, and Alusat will return a feasibility review and quotation. Use the quote form below or email our engineering team directly at hank@alusat.com.