Aluminum Extrusions — Custom Profiles, Ready for Assembly
Since 2000, SanCo Sales has helped engineers and buyers turn extrusion concepts into production-ready parts. We align alloy, temper, die strategy, and downstream fabrication so first articles look like production—and production looks like reorders. Whether you need raw profiles, tight-tolerance machining, formed frames, or fully finished assemblies, we match the right press and partner to your envelope, volumes, and finish requirements. One accountable point of contact. ISO-aligned quality. Prototype → production. Domestic and overseas options—quoted side by side so you can pick speed, cost, or a balance.
Why Aluminum Extrusions (and Why Teams Choose SanCo)
- Strength-to-weight wins. Extruded aluminum delivers stiffness without mass. With the right alloy/temper and profile design, you can replace complex weldments and reduce part count. We flag hotspots—wall thickness transitions, thin ribs, unsupported corners—so you avoid tooling rework.
- Design freedom with fewer operations. Near-net profiles allow features like slots, channels, and internal webs to come off the press. That means less machining, fewer fasteners, and simpler assembly. We’ll advise where a small die change saves hours downstream.
- Finishes that work and look right. From clear/black anodize to architectural powder coat and high-polish 6463 trims, we align finish to environment and brand. We can send chips/samples early so color and gloss are never a surprise.
- Scales from pilot to volume. We’ll quote prototype dies when speed matters, then plan the production die strategy once geometry is locked. When volume climbs, we coordinate capacity and pack-out so your releases flow.
We de-risk the journey by aligning alloy/temper, die strategy, and downstream fabrication. Your first articles look like production—and production looks like reorders. If extrusion stops being the smartest path, we pivot to CNC machining, castings, or overseas sourcing to hit your targets.
Related services: CNC Machining • Castings • Overseas Sourcing
What We Source
Send your drawing and targets—we’ll compare process, tooling, and unit cost to recommend the best path.
Custom Profiles
Design-for-extrusion guidance, alloy/temper selection, and die design. We review CAD for thin walls, unsupported features, and cooling considerations.
Tight-Tolerance Fabrication
Cut-to-length, drilling, CNC machining, tapping, countersink/counterbore, deburr. We’ll mark critical faces and datum schemes so inspection is predictable.
Bending & Forming
Stretch forming and roll bending for frames, arcs, and radiused enclosures. We validate springback on samples and build go/no-go checks where needed.
Finishing & Assembly
Anodize (Type II/III), powder coat, paint, brushing/polish, inserts, hardware, sub-assembly, and kitting. One PO, one accountable partner.
Materials, Tempers & Finishes
Common alloys include 6061, 6063, 6005, 6082, and 6463. We’ll match the choice to strength, machinability, surface appearance, and corrosion needs. Typical tempers are T4/T5/T6/T66 depending on mechanical targets and finishing plans. Finishes range from clear/black anodize for corrosion and wear, to powder coat and painted systems for color coverage and durability. Decorative applications may leverage 6463 with high-polish capability. For industrial parts, we balance anodic thickness with cost and environment (indoor vs outdoor, coastal exposure, chemical contact).
Tolerances, Capability & Quality
At-a-Glance
Directional guide; we quote realistic numbers by part and material.
Quality Stack
- ISO 9001 systems • PPAP/FAI on request
- Dimensional reports • CMM as needed
- Material certs • Traceability
Inspection aligned to your drawing and environment.
Extrusion tolerances depend on profile envelope, wall thickness, alloy/temper, and die quality. Secondary machining tightens critical interfaces; we’ll recommend which faces to machine and which can remain “as extruded.” We provide realistic tolerance windows at quote—no “catalog numbers” that evaporate on the shop floor.
Start Your RFQ
Attach prints or a model if you have them. Give us the targets—we’ll come back with an honest plan and timeline.
Prefer email? Send prints to info@sancosales.com and we’ll reply with DFM + timeline.
Industries We Serve
Architectural (frames, mullions, trims), Electronics (heat sinks, enclosures), Industrial (machine guarding, conveyors), Automotive (lightweight structures and trim), Aerospace (documentation-heavy profiles), Solar & Energy (racking and thermal management). If extrusion stops being the smartest path, we pivot to CNC machining, castings, or overseas sourcing to hit your targets.
Architectural
Frames, mullions, trims with durable finishes.
Electronics
Heat sinks, enclosures, cable channels.
Industrial
Machine guarding, conveyors, structural profiles.
Automotive
Lightweight structures and trim.
Aerospace
Precision extrusions with documentation.
Solar & Energy
Racking, frames, heat management.
Domestic vs Overseas Extrusions
| Option | Strengths | Best For |
|---|---|---|
| Domestic | Faster DFM cycles, quick die tweaks, finish trials, and shorter transit. | NPI, frequent revisions, architectural color matching. |
| Overseas | Die and unit-price leverage at volume with clear QA and packaging upfront. | Stable programs with forecast; buffer inventory when releases spike. |
We’ll present both paths with lead time, cost, and risk side-by-side so you choose eyes-wide-open.
“SanCo turned our extrusion concept into finished assemblies in one go—no ping-pong between vendors.”
Free Download: Extrusion DFM & Tolerance Guide
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Request PDFAluminum Extrusions: Frequently Asked Questions
What alloys and tempers should I choose?
6063 excels for architectural surfaces and anodize quality; 6061 and 6082 bring higher strength and machinability; 6005 bridges strength and extrudability; 6463 is best for bright polish. Temper is driven by strength and finish sequence—T5/T6/T66 are common. We’ll propose the best mix for your geometry and environment.
How do you handle long straightness or tight flatness?
We combine press selection, support/handling, aging control, and post-process straightening. For critical faces we’ll plan secondary machining and inspection with fixturing to prove flatness or parallelism where it matters.
Can you bend or form complex frames?
Yes—stretch forming and roll bending with springback characterization early. We often cut “witness samples” to confirm radii and cosmetic behavior before releasing full lots.
What’s realistic for tolerances?
As-extruded dimensions follow profile and press capability; small features and thin walls carry larger variation. We’ll flag which features should be machined versus left “as extruded,” and we’ll quote a tolerance window that aligns to your actual geometry, not a generic chart.
How fast can you move from prototype to production?
Prototype dies can be cut quickly for learning and early parts. Once geometry is locked, we define the production die strategy, finish plan, and pack-out so scale-up is controlled.
Do you provide finishing and assembly under one PO?
Yes. We manage anodize/powder/paint, inserts, hardware, and kitting so parts land line-ready. Documentation and inspection travel with the lot.