The Cost of Custom Aluminum Extrusions: 5 Key Factors

Ordering a custom aluminum extrusion can be the right choice when standard inventory doesn't meet your specific needs.

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Whether you need a unique profile, an unusual alloy, or a special surface finish, understanding the costs associated with custom aluminum extrusions can help you better manage your project’s budget. Here, we discuss five key factors that impact these costs.

#1 Die and Tooling Costs

For custom profiles, manufacturers must create new dies from scratch. This adds to the overall cost, especially for complex geometries that require more time and labor to produce.

How Much are Die and Tooling Costs?

Tool costs for extrusion dies in architectural and industrial applications can range from $400 to $1,000. Large parts made on 2,000-4,000 ton presses could have tool costs as high as $2,000.

Sometimes manufacturers refund tool costs if a stipulated amount is purchased within 2 years, and most do not charge for replacement tools after their useful life if orders continue. Normal tool turnaround time is 3-4 weeks, with production following within a week of sample approval.

Factors Increasing Die Cost

• The Circumscribing Circle Diameter (CCD): Designs with CCDs between 1 and 10 inches are less expensive than those over 10 inches.
• Die Symmetry: Symmetrical profiles are easier and cheaper to produce, as they allow for uniform material flow through the die.
• The Joining Method: Sometimes, complex profiles are divided into simpler ones that are joined later. This reduces die complexity and cost.

#2 Current Aluminum Cost

The base cost of aluminum significantly impacts the final price of custom extrusions. Raw aluminum prices fluctuate due to global demand, industry trends, and electricity costs. Locking in a bulk purchase rate might be beneficial for ongoing production needs.

Different aluminum grades have varying costs, and manufacturers may not stock unusual alloys, increasing the price for special orders.

How Much Does Aluminum Cost?

The cost of aluminum has varied from $1,500 to $3,500 per metric ton in recent years due to political events and environmental restrictions.

#3 Labor and Production Costs

Manufacturing labor costs are often stable and based on regional conditions. Additional production costs include operating overhead, equipment, maintenance, and utilities. While manufacturing abroad can incur increased shipping costs, these are typically offset by larger production volumes.

Gabrian International primarily produces aluminum extrusions in India, where labor costs are relatively low compared to the US or Europe.

#4 Surface Finishing and Secondary Operations

Secondary operations like surface finishing can enhance appearance or mechanical properties. CNC machining, temper treatments, and various surface finishes are common post-extrusion processes.

Machining

CNC machining is used for creating holes or shapes not possible through extrusion alone. Bending is another method for creating physical alterations.

Temper Treatments

These treatments change the mechanical properties like strength and hardness of aluminum products. Normally, there is no extra charge for different tempers if volumes are high enough.

Surface Finishes

Surface finishes improve protection and appearance. For instance, powder coatings provide a durable finish, while anodizing enhances corrosion resistance. (Related: Should You Anodize or Powder Coat?)

Costs of Surface Finishing and Fabrication

Anodizing and powder coating costs range from $1,200 to $1,400 per metric ton, while alodine finishing costs about $800 per metric ton. Fabrication costs vary with complexity; simple drilling ranges from $200-$300 per metric ton.

#5 Production Volumes

Buying in bulk often reduces the cost per unit. For instance, the basic die and tooling costs are spread over more parts, decreasing the cost per item.

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Bonus Factor: Logistics Costs

Transportation logistics significantly affect the final cost. The COVID pandemic highlighted how shipping disruptions can cause major fluctuations in costs. Additionally, local duties and tariffs on imported products can raise the overall expense.

How Much Does International Shipping Cost?

Shipping a 40-foot container from Asia to North America has varied from $8,000 to $20,000, driven by factors like political uncertainty and the pandemic. The China airtight sliding door company also considers these factors for optimal pricing strategies.

Optimizing the Cost of Custom Aluminum Extrusions

The total price of custom aluminum extrusions is influenced by many factors, some predictable and some not. Gabrian’s Aluminum Extrusion Guide can help you optimize your design to minimize production costs. Our experts can also advise on the best combination of alloy, surface finish, and temper treatment to achieve your project’s goals within budget.

Leverage our custom aluminum extrusion capabilities for your next project to get a rapid turnaround for high-quality extrusions that meet your budgetary requirements.