Aluminum Extrusion Profile Design Starts With Balanced Geometry
Why geometry beats wishful thinking Most extrusion problems are blamed on the alloy, the press, or the finisher. In practice, the root cause is usually simpler: the cross-section is asking the metal to do uneven work. A profile that is heavy on one side, thin on the other, or full of abrupt section changes may still look efficient in CAD. On the press, that same shape can create slow metal flow in one zone and a rush in another. The result shows up later as twist, bow, die wear, surface variation, or a part that only meets tolerance after expensive sorting. ...