Custom Aluminum
Extrusion Services
From standard T-slot profiles to custom complex shapes. DFocus PROTOTYPE specializes in low-volume aluminum extrusion, offering rapid production and precision post-machining.
- No Minimum Order Quantity (Low Volume Focus)
- Custom Dies & Standard Profiles Available
- Full Post-Machining & Finishing (Anodizing)
Custom dies + CNC post-machining + anodizing available.
How Aluminum Extrusion Works
Aluminum billets are heated and forced through a die to create continuous cross-sectional shapes, like squeezing toothpaste.
Standard Profiles
We stock a wide range of common shapes to speed up your project:
- • T-Slot (2020, 3030, 80/20)
- • Square / Circular Tube
- • Solid Round / Square Bar
- • L-Shape / U-Shape / C-Shape
Custom Profiles
Need a unique shape? We design and manufacture custom dies for your specific cross-section. Ideal for heat sinks, specialized enclosures, and structural framing.
*Low tooling costs for custom extrusion dies.*
Materials & Applications
Aluminum Alloys
- 6061Structural, high strength.
- 6063Architectural, good surface finish.
- 7075Aerospace grade, very strong.
Common Uses
- Heat Sinks & LED housings
- Structural Frames (Workbenches)
- Window & Door frames
- Linear motion rails
- Automotive trim
Finishing Options
- Anodizing (Clear, Black, Color)
- Powder Coating
- Shot Blasting
- Polishing / Brushing
- Laser Engraving
Why Choose Dfocus Prototype for Extrusion?
Most extrusion mills require huge minimum orders (500kg+). We bridge the gap for prototypes and small batches.
- Low Volume FriendlyWe accept small orders that large mills reject.
- One-Stop ShopWe extrude, cut, CNC machine (drill/tap holes), and finish your parts all in house.
- High QualityFull QC certified quality control on every profile.
Material Yield Efficiency
*Extrusion pushes nearly all material into the final shape, drastically reducing waste and cost for linear parts.*
Compare Project CostsAluminum Extrusion FAQ
What is the minimum order for extrusion?
Unlike traditional mills, we do not have a strict weight minimum. We specialize in low-volume prototype extrusion (e.g., a few meters or tens of parts) to validate your design.
Which alloy should I choose? 6061 or 6063?
6063 is the most common for extrusion; it has a better surface finish and is easier to extrude complex shapes. 6061 is stronger and better for structural applications but has a slightly rougher finish.
Can you do custom anodizing colors?
Yes. While clear (silver) and black are standard, we can match custom colors for anodizing or powder coating to meet your branding requirements.
Custom Profiles, Fast
Upload your profile design (DXF/DWG/STEP) for an instant extrusion and machining quote.
Get Extrusion Quote