Custom Aluminum Extrusion Services
From custom profile design to machining, finishing, assembly, and global delivery. We are your long-term supply chain partner, not just a parts manufacturer.
Why Procurement Leaders Choose Aluminum Extrusion
Beyond just shaping metal, custom extrusion is a strategic choice for reducing total manufacturing costs and simplifying supply chains.
Reduce Manufacturing Cost
Significantly lower costs compared with CNC machining from solid blocks, especially for long profiles and constant cross-sections.
Custom Cross Sections
Design complex, unique geometries that incorporate features like screw bosses and t-slots, eliminating the need for welding.
Lightweight Structures
Achieve an excellent strength-to-weight ratio, critical for automotive, aerospace, and industrial automation applications.
Scalable Production
Cost-effective tooling allows for seamless scaling from initial prototyping runs to high-volume mass production.
Integrated Manufacturing
We consolidate your supply chain: Extrusion + Precision CNC Machining + Surface Finishing + Final Assembly under one roof.
Reliable Supply Chain
Long-term production support with inventory programs, ensuring you have the right parts exactly when you need them.
Best Applications for Aluminum Extrusion
Extrusion is the optimal process when your design requires consistent cross-sections over a specific length. It is widely used for:
- Long Structural Components
- Equipment Frames
- Linear Rails & Guides
- High-Performance Heat Sinks
- Electronics Enclosures
- LED Lighting Housings
- Industrial Automation
- EV Battery Components
- Solar Mounting Systems
Need Help Choosing a Process?
Aluminum Extrusion
Best for: Constant cross-sections, long profiles, structural frames, heat sinks. Low tooling cost ($500-$2000), excellent for scaling.
CNC Machining
Best for: Complex 3D geometries, varying cross-sections, very tight tolerances. No tooling cost, but higher per-part cost for large volumes.
Sheet Metal Fabrication
Best for: Thin-walled enclosures, brackets, panels. Involves bending and welding. Less structural rigidity compared to extruded profiles.
Custom Profile Capabilities
We manufacture precision OEM aluminum profiles tailored to your exact engineering requirements.
Need Help Designing an Extrusion?
Our engineering team provides comprehensive Design for Manufacturability (DFM) support to ensure your profile is optimized for production, functionality, and cost.
Extrusion Alloys Tailored to Your Application
We stock and extrude a variety of 6000-series aluminum alloys, selected based on your mechanical, thermal, and finishing requirements.
6063 Aluminum
The Architectural Standard
Provides an excellent surface finish and is highly responsive to anodizing. Ideal for architectural trims, window frames, and custom heat sinks where aesthetics matter.
6061 Aluminum
The Structural Workhorse
Offers higher strength and excellent machinability. The go-to choice for structural frames, automotive components, and parts requiring heavy CNC post-machining.
6005A Aluminum
High-Stress Applications
A versatile structural alloy offering better extrudability than 6061 while maintaining high strength. Perfect for ladders, automotive structural parts, and rail transport.
6082 Aluminum
Heavy-Duty Industrial
The highest strength alloy in the 6000 series. Primarily used in highly stressed applications including trusses, bridges, cranes, and heavy-duty industrial systems.
In-House Secondary Operations
Raw extrusions rarely go straight to assembly. Our integrated CNC machining centers transform raw profiles into precise, ready-to-use components, saving you the hassle of managing multiple vendors.
Professional Surface Finishing
Protect your extrusions from corrosion and achieve the exact aesthetic required for your final product.
Need Consistent Colors?
We understand the frustration of mismatched anodized parts. We offer strict batch-to-batch color control processes and limit samples to ensure visual consistency across large production runs.
Value-Added Assembly Services
Reduce your internal labor costs and simplify receiving. We deliver Ready-To-Install Products directly to your production line or warehouse.
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Hardware Installation
Pre-installing helicoils, pins, threaded inserts, and gaskets.
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Mechanical Sub-Assembly
Joining profiles using fasteners, corner connectors, and brackets.
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Electrical Assembly
Integration of basic wiring, LED strips, or thermal pads for heat sinks.
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Custom Packaging
Kitting, individual retail packaging, or specialized industrial crating to prevent transit damage.
Understanding Extrusion Dies
Clear answers to the most common questions procurement teams have about custom extrusion tooling.
Die Cost
Extrusion tooling is highly affordable. Solid dies typically range from $500 to $1,500, while hollow dies range from $1,000 to $3,000 depending on complexity and press size.
Lead Time
Standard lead time for cutting a new extrusion die and producing the first article inspection (FAI) sample is typically 15 to 20 days.
Die Ownership
You own the die. Once the tooling fee is paid, the die belongs entirely to your company and is exclusively used for your production runs.
Die Life
A typical die can produce between 10 to 15 tons of aluminum before wearing out. We monitor die health closely during production.
Die Maintenance
We cover all routine maintenance, cleaning, and polishing of the die. If a die wears out during its expected lifecycle while in our facility, we replace it at our cost.
Design Changes
Minor modifications (like opening up a tolerance) might be possible on an existing die. However, adding material or major feature changes usually requires cutting a new die.
Rigorous Quality Assurance
Aluminum extrusions are prone to twisting, bowing, and dimensional variations if not controlled properly. Our ISO 9001 certified facility utilizes strict protocols to ensure your profiles meet exact specifications.
Industries We Serve
Delivering high-performance extruded components to demanding global industries.
Industrial Automation
Solar Energy
EV Charging
Medical Equipment
Electronics
LED Lighting
Telecommunications
Construction Systems
Success Stories
How our engineering and manufacturing solutions deliver measurable results.
Industrial Frame System
Redesigned a heavy steel welded frame into an interlocking custom aluminum extrusion system for an automation client.
EV Battery Housing
Integrated mounting channels directly into the extrusion profile, eliminating the need for secondary drilling and tapping.
LED Lighting Profile
Consolidated extrusion, anodizing, and final cutting from three separate vendors to our single-source facility.
Need Stable Supply? We Manage Inventory.
Stop worrying about long lead times and supply chain disruptions. For high-volume clients, we offer comprehensive inventory management programs utilizing our USA warehouse support.
Why Partner With LK Tools?
We provide a true Prototype to Production solution. Stop managing multiple vendors for a single part.
One Supplier For Your Entire Process
- Custom Extrusion Dies
- Precision CNC Machining
- Surface Finishing (Anodizing/Coating)
- Mechanical & Electrical Assembly
- Custom Packaging
- Global Logistics & DDP Shipping
Frequently Asked Questions
What is the minimum order quantity (MOQ)?
How much does an extrusion die cost?
How long does tooling take?
Can you provide anodizing and machining?
Can you assemble finished products and stock inventory?
Who owns the extrusion die and can it be transferred?
Can you ship DDP?
Need Custom Aluminum Extrusions?
Upload your drawings today to receive DFM feedback within 24 hours, get a competitive quote, and start production faster.
Carrollton, TX 75006, USA