Aluminum extrusions are versatile, finding use in a wide range of industries and applications. But that diversity of applications also means your supplier's inventory of standard profiles won't cover every need.

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Many product designers encounter unique situations. You might need non-standard shapes, specialized finishes, or uncommon alloys. So creating custom aluminum extrusions makes the most sense.

If you want to create custom extruded profiles, you must be aware of the most essential design considerations. This article lists our top five extrusion design tips to set you on the right path. These tips will help you avoid quality issues and manage costs when producing custom extrusions.

Tip #1 ' Choose the Right Alloy for Your Application

Materials databases list an impressive number of aluminum alloys for designers. It's easy to get caught up in choosing the one that provides the best physical properties for your application. But you should also carefully consider the impact of extrudability.

Choosing one of the more popular aluminum extrusion alloys can improve extrusion characteristics. Doing so can also minimize defects and lower production costs.

These alloys may have lower strength, hardness, or wear resistance than some alternatives. However, there are still ways to fine-tune the aluminum's properties after extrusion. Heat treatments and tempering can help you get the best qualities for easy manufacturing and improved durability.

Learn about extrusion alloys '

Tip #2 ' Select the Most Appropriate Surface Finish

Another great way to improve the performance of custom extruded aluminum products is to apply surface finishes. There are several common types of aluminum finishes, each offering different benefits.

Finishing can improve the durability or aesthetics of your custom extrusions ' and some finishes can even do both!

For example, anodizing your aluminum extrusions can improve corrosion and wear resistance. At the same time, it allows you to dye the aluminum in various metallic colors.

Learn about aluminum surface finishes '

Tip #3 ' Understand the Costs of Custom Extrusions

Getting good value for your money is essential to a project's success. That's why it's invaluable to understand the different factors that affect the cost of custom extrusions.

The costs to produce custom aluminum extrusions are strongly affected by various factors:

• Type of aluminum alloy used
• Size and complexity of the custom extrusion die (sometimes tooling costs are refunded with high volumes)
• Current cost of aluminum
• Local labor costs
• International shipping rates
• Discounts for larger production volumes (or markups for smaller batches)
• Additional time and specialized equipment needed for temper treatments or surface finishes

Understanding how and why different elements affect the price of custom aluminum extrusions is vital. This way, you can make better decisions and get the best value.

Learn about custom extrusion costs '

Tip #4 ' Learn About Extrusion Joining Methods

Including joints in your custom extrusion design can be surprisingly helpful. Sometimes, a single aluminum profile can be too large, asymmetric, or complex. In these cases, joining multiple extrusions together makes manufacturing easier and cheaper.

Extrusion joining methods can also improve the modularity of your product. They increase its customizability during use and make handling during installation more manageable.

There is even the option to use specialized hinge joints that allow for limited rotation at the joint. Doing so adds flexibility to assemblies.

It's valuable to know the different extrusion joining methods. They can improve the versatility of your custom aluminum extrusion profiles. Choosing the most suitable joining method can also reduce manufacturing costs.

Learn about extrusion joining methods '

Tip #5 ' Design for Manufacturing Efficiency

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The value of efficient manufacturing is obvious: lower production costs and improved product quality. But how do you optimize your design to capture these benefits?

There are many avenues to optimizing the aluminum extrusion process. Choosing formable alloys, designing the profile to distribute stresses evenly, and using modeling software are great ways.

There is much to understand about designing custom aluminum extrusions, so we naturally can't cover everything here. To learn more, check out our aluminum extrusion design guide, which we've packed with helpful information for designers.

It's also essential to involve your extruder in the process as early as possible. This way, you can get the perspective of manufacturing engineers with relevant experience. Feel free to learn more about our custom aluminum extrusion services and contact us if you need help. Our engineers can provide feedback on the manufacturability of your design.

I am always trying to find new ways to recycle the waste we generate at home to save it from going to recycling centres or landfills. In this project, I am sharing how I upcycled some aluminium drink cans into Shimmering Aluminum Can Art. My idea was to create an image of a star and then cover it with small circles cut from aluminium drink cans.

The circles are so light that the slightest breeze will make them move giving a shimmering effect like a twinkling star. Click here to see the moving aluminium can art in action.

This was my first time trying aluminium can art doing it this way so I started small. I was not sure how long it would take and I wanted to see how time-consuming it would be. But it turned out to be a surprisingly quick project to do. I will share some of the tips I picked up along the way and also the mistakes I made.

Contact us to discuss your requirements of Custom Aluminum Can. Our experienced sales team can help you identify the options that best suit your needs.

How to make Shimmering Aluminum Can Art

Materials needed

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• Aluminium cans
• Hole punch (circle-shaped)
• Wooden board (size of your choice)
• Nails
• Hammer
• Paints (if you want to add colour)
• Sandpaper (for smoothing edges)
• Safety gloves and goggles
• Drop Saw/jig saw/hand saw
• Utility knife/scissors
• Scissor clamps

Cutting the cans

Working with aluminium cans can be sharp and potentially hazardous. Wear safety gloves and goggles to protect your hands and eyes. You will need around 20 cans for a board of around 45cm square. Start by cleaning the cans thoroughly, removing any residue or liquid. Once cleaned, cut off the tops and bottoms of the cans to create cylinders. Use a utility knife or scissors for this step. Next, cut down the cylinder so you have a flat piece of aluminium to work with.

Next, using a circle hole punch cut out circle shapes from the aluminium can. The circle punch I used was 2.5cm but they do come in other sizes. I found it easier to cut out the shapes all around the outside, then cut away the excess and do the same again.

Drilling the holes

The hole size will depend on the size of the nails you will be using. The hole size should only be a fraction larger than the nail so you have room for movement. I did do a test run and just nailed the circle straight to the board without drilling the hole first but this did limit the movement of the circle. The idea of drilling a hole in each circle did not go down too well so I found a way to drill them in batches. I pilled about 20 circles together and clamped them with some wood clamps.

I placed a block of wood under the pile and drilled them all at the same time. For the next pile, I used one of the circles from the previous pile as a template so all the holes were in the same place.

Prepare your board

I used a piece of plywood 45cm square as the base for my project.

Making the wooden star

The idea I had in my head was to make a wooden star to go onto the board to make the star stand out more from the background and add dimension. I did not want to spend too much time making a star so I went with a simple star created in the same way as you would when making a barn quilt.

This is done in a few quick steps. Start by cutting some plywood into 7cm lengths, I used offcuts for this step.

I clamped 4 pieces together and cut the ends to a 45-degree angle.

Next, I added a straight cut to the wood leaving me with pieces of wood at 17cm.

To get the layout of the star you need to draw a line from each corner across the board, this will help you centre the star.

I repeated this step with the 45-degree angle cut from the other side of the drop saw, this will give you the opposite side of the star. I did it this way because only one side of plywood has a nice surface and I did not want to do lots of sanding.

To work out the length of the smaller pieces I laid out the design and marked the wood where the star matched up and cut it to size.

The smaller shapes will slot into the gaps as shown in the image below.

Painting the wood

Next, I painted all the wood black ready to be glued into place on the board. If you are going to hang your project outside in the elements I would recommend that you seal the wood with some outdoor polyurethane to protect the surface. This was one of my first mistakes It was here I should have painted the star gold so it would stand out more against the black. But I only realised this after I started adding the gold circles.

Next, I added the pencil lines to the board again so I could line up the star before glueing it in place.

To glue the star to the board I used some wood glue and a blob of hot glue to hold it in place while the wood glue dried.

Adding the aluminium can circles

Here comes mistake number 2, I should have used nails with larger heads on them. These ones worked great but after watching the wall hanging get a really big gust of wind I did notice that one circle fell off. That particular nail did seem to have a smaller head than the others but I felt if I were going to do it again I would go for larger ones.

I started adding the circles from the top of the board working my way down. After adding the first nail and hitting my fingers I went searching in my workshop for something to hold the nail while hammering them in place. I came up with two options that worked. The first was small longnose pliers and the option I went for was these scissor clamps.

This step went surprisingly fast, I did not mark out the board I simply added the circles one next to the other.

I wanted the star to really stand out so I added so texture to the aluminium for the star. I did this by using an embossing folder and press to emboss the aluminium. Before I embossed and cut out the circle I used gold spray paint to paint the aluminium.

Once embossed I followed the same steps as above for cutting them out and adding the hole. I have used this technique before on another Aluminium Can Art project when I decorated a shop mannequin using embossed recycled cans.

When I was adding the gold circle I had an overlap and decided to cut the circle so the star stood out. But in hindsight, it was easier to leave the outline of the star visible and just have the circles on the inside.

Hanging your board

To hang the board I attached a keyhole bracket to the back so it slip onto a screw fitting to the wall. Before I mounted the board to the wall I tipped the board forward so all the circles fell to the head of the nail so that the breeze could get under the aluminium circles. Now you can just sit back and wait for the breeze and admire your Aluminium Can Art.

If you have some sheet of aluminium can left over and you do have an embossing press. Here is another Aluminium Can Artwall hanging I made using recycled aluminium cans and pop rivets.

Recycling project ideas

If you are looking for more unique project ideas check out these. My good friend Michelle from A crafty mix made this really awesome handbag planter from recycled pallet wood.

Why not get an early start on your Halloween decorations with these uniquely decorated recycled bottles?

If you are looking for any of the items used in this project, please consider using our links. By clicking on the links we will earn a small commission at no extra cost to you.  Which helps us come up with new and exciting ideas to share with you.

If you want to learn more, please visit our website Custom Tin Cans.