Drawing-Based Custom Manufacturing
Custom Aluminum Extrusion & Secondary Machining
Aluminum extrusion forms a continuous profile by pushing a billet through a shaped die. It is suited to components with a repeated cross-section, such as rails, frames, tubes and enclosure bodies. JUNCHU coordinates profile and die review, cut lengths, CNC features and finishing so the profile becomes a usable component rather than only a raw length.
Profiles · Rails
Frames · Housings
PART TYPES
Aluminum Alloys
Grade & Temper Review
MATERIAL ROUTES
Finishing · Inspection
Assembly
DOWNSTREAM SUPPORT
Section · Temper
Cut Length
PROFILE INPUTS
From Profile Section to Finished Component
Extrusion, secondary machining & finishing
Extrusion creates the main section. Features that vary along its length—cross holes, pockets, threads and end details—usually require secondary processing.
Profile & Die Review
PROCESS & PROJECT REVIEW
The die defines a constant cross-section. Review open or hollow geometry, wall balance, radii and features such as channels or screw ports. Alloy and temper affect strength, extrudability and finish; narrow gaps and highly uneven walls can complicate the route.
01
Cutting & Machining
PROCESS & PROJECT REVIEW
Saw profiles to length, then add drilled and tapped holes, slots, pockets and end milling. Long thin sections need support during clamping. Define whether hole positions reference the cut end, a profile face or a functional assembly datum.
02
Finishing & Assembly
PROCESS & PROJECT REVIEW
Anodizing can retain a metallic appearance; powder coating provides a specified opaque color and texture. Both need a plan for contact marks, masking and final fits. Review end caps, brackets and fasteners using the finished profile dimensions.
03
Before Manufacturing
What We Review Before Quotation
Agree the requirements below before committing to tooling, processing or a production batch.
01
Profile Drawing
Send a dimensioned cross-section, cut length and 3D data where available.
02
Alloy & Temper
Choose the material condition for strength, extrusion suitability and surface requirements.
03
Tooling & Quantity
Tooling charges, minimum run quantities and sample schedules are quoted per profile.
04
Straightness & Fit
Identify mating sections, sliding interfaces and straightness requirements.
05
Secondary Features
Specify holes, threads, end milling and the reference surfaces for machining.
06
Finish & Packing
Agree color samples, cosmetic zones and protection for long or appearance-sensitive parts.
Common Aluminum Profile Applications
Where a repeated section adds value
01
Enclosure Bodies
Continuous channels and internal rails can locate boards or covers. Machine connector openings and threaded ends after extrusion.
02
Frames & Rails
Profiles provide a repeatable structural section. Straightness, joint position and finish influence assembly alignment.
03
Tubes & Telescopic Parts
Mating sections need controlled clearance, straightness and finished surfaces. Review sliding fit after anodizing or coating.
04
Lighting & Heat-Sink Profiles
Fins, mounting channels and cover interfaces can share one section. Thermal performance depends on the complete design and use.
Start Your Custom Extrusion Project
Start with the part requirements, review the manufacturing route, then agree inspection and delivery before production.
Section & Die Review
Provide the profile cross-section, alloy, temper, cut lengths and expected order quantity. Review die cost and profile feasibility together.
Sample Profile
Check the first profile for section dimensions, straightness and the interfaces needed by machining or assembly.
Secondary Operations
Add the drawing-defined holes, threads, end features and finish, keeping the specified datum strategy.
Fit & Protection
Verify the agreed mating features and protect long lengths and cosmetic faces against rubbing or impact in transit.
Project Planning
Planning a Custom Extrusion Project
Review the section, die investment and finished component as one connected manufacturing route.
Standard Section or Custom Die
An existing section may avoid new die development when its geometry suits the application. A custom section can integrate channels, rails and mounting features, but requires review of wall balance, cavities and extrusion feasibility. Compare the whole component cost, including machining and assembly, rather than only the profile price.
Quantity and Cost Drivers
Section complexity, alloy and temper, purchased length, run quantity and expected repeat demand influence the quotation. Cutting loss, machining setups and finishing can add significant downstream cost. Separate die charges, extrusion supply, cut-to-length work and secondary operations so the scope is easy to compare.
Validate the Finished Interface
A profile sample confirms the section, but does not automatically validate a machined, coated assembly. Review straightness, twist, hole locations and mating clearances at the finished-part stage. Telescopic or sliding parts should be assessed together with their guides, stops and intended travel.
Protect Long and Cosmetic Parts
Specify cut lengths, allowable contact marks, visible faces and packing orientation. Long sections may need support and separation to limit handling damage. Agree identification, bundle quantities and whether protective film must remain in place for later machining or assembly.
Component images are 3D concept illustrations of representative parts.
Before You Start Your Project
Common Questions
Before an RFQ
Review the information needed for a clear quotation, practical process planning and agreed inspection requirements.
What information should I include in an RFQ?
Provide the profile cross-section, alloy and temper, cut lengths and quantities per length. Include a finished-part drawing for holes, threads or milled features, plus straightness, mating clearances and visible surfaces. State the finish and expected repeat demand so die costs and production quantities can be reviewed together. If you already own a die, share its drawing and ownership details for a compatibility review.
Do custom profiles require new tooling?
A new cross-section may require an extrusion die. Tooling cost and minimum run quantity depend on the section, alloy and production plan. Confirm the profile drawing and sample approval arrangements before tooling begins.
Can extrusions include machined features?
Yes, the project can be reviewed for cutting, drilling, tapping, slots and end features. Identify the reference faces and mating dimensions so extrusion tolerances and secondary machining are considered together.
How do I specify straightness and a sliding fit?
Provide the mating profile or assembly drawing and identify the functional travel and contact areas. Straightness, twist, coating build and clearance should be reviewed as a combined requirement.
How should I specify surface finish and appearance?
State the finish type, color reference, texture, cosmetic surfaces and areas that must remain untreated. For appearance-sensitive parts, agree on a physical sample and acceptance conditions. Coating thickness, alloy and pretreatment can affect dimensions and color; review these together with the drawing.
Separate Profile Requirements from Finished-Part Requirements
| Project input | Profile-level question | Finished-part question |
|---|---|---|
| Cross-section and material | Is a standard section suitable, or is a new die needed? | Which interfaces require secondary machining? |
| Length and straightness | How will the supplied section and cut length be controlled? | Where are the assembly datums and final locating faces? |
| Telescopic or sliding fit | Which section variations affect clearance? | What travel, overlap, guide material and finish must be checked together? |
| Surface treatment | Which alloy and pretreatment support the required appearance? | Which faces, threads or contact surfaces need masking or protection? |
Approve a representative combination
For a sliding assembly, check the actual mating sections, guide components and intended finish together. A single nominal clearance or an unfinished profile sample does not describe all of the conditions that affect movement.
Use the RFQ checklist to bring these decisions into one controlled enquiry package.
Ready To Start Your Project?
Start With Your Drawings - or Tell Us What You Need
Share drawings, photos or sketches with your quantity, material, finish and target date. We review the available information, clarify technical requirements and confirm quotation timing. Complex or multi-process projects may require additional review.
Discuss confidentiality and NDA requirements before sharing sensitive project files.