Quick AnswerFive key rules for extrusion design: (1) uniform wall thickness throughout the profile (0.8-6mm, vary no more than 50% between sections), (2) inside corner radii of 0.5mm minimum, (3) avoid deep narrow channels (depth-to-width ratio under 3:1), (4) symmetrical profiles extrude faster and more consistently, and (5) balance solid and hollow sections. Following these guidelines reduces di...

Quick AnswerAluminum extrusion provides five key advantages: (1) custom cross-sections designed for your specific application, (2) excellent strength-to-weight ratio (comparable to steel at 1/3 the weight), (3) natural corrosion resistance, (4) low tooling cost ($500-$3,000 for extrusion dies), and (5) infinite length capability. Combined with good thermal conductivity and full recyclability, extr...