Let’s face it: most of the products we use in our day-to-day activities, be it in manufacturing, automotive, or general use, have some aluminum. This is because aluminum is known to be a highly versatile metal that SME manufacturers can use to create a variety of parts.
Now, to achieve the aluminum-made parts, various manufacturing methods are involved, and of course, you choose the one you feel works best for the kind of product you are making.
The big question is, which manufacturing method is better, and what are the notable differences between aluminum intrusion and other traditional manufacturing methods? Read this guide, we’ve answered it all!
What is Aluminum Extrusion?
Aluminum extrusion is an economical metal shaping industrial process which is primarily used to engineer erect and long parts (majorly cross-sectional profiles). This method is utilized in creating t-shapes, l-shapes, straight tubes, and rectangular shapes.
This process utilizes high pressure to create well-shaped items where manufacturers strategically guide a piece of aluminum through a metal die to reshape the metal and attain a desired form.
Aluminum extrusion, being a fairly straightforward process, is ideal for creating various shapes that can be extruded, including solid ones with no enclosed voids or openings, hollow shapes with one or more voids, and semi-hollow partially enclosed and void.
This manufacturing process is widely utilized in various industries, such as the automotive world, electronics, energy, aerospace and architecture, and more.
Unlike other popular manufacturing methods, any items produced using the aluminum extrusion process are known to have a brilliant surface finish. In addition, they are more robust in nature. Examples of such products include windows, door frames, sinks, and light-tracked equipment.
What are Traditional Manufacturing Methods?
If one discusses traditional manufacturing methods in the manufacturing arena, they simply refer to the aluminum die casting method. This modern method is used to create high-quality and consistently shaped parts.
Die casting subjects high pressure on the metal as the temperature decreases. The final product will have a consistent shape and durable structure.
Traditional manufacturing methods include sand casting, mold casting, and investment casting. All aforesaid casting methods have their own unique features, so you can always select the one that works for the design part you are aiming to produce.
No matter what the casting method is, aluminum alloy has to be melted and then poured into molds. Once done, they are then left to cool and solidify.
With aluminum casting methods, multiple products can be produced simultaneously, which is a great advantage for companies needing items in huge volumes.
Aluminum Extrusion vs. Traditional Manufacturing Methods
Now, as seen above, these two primary manufacturing methods are quite distinct from each other. Understanding the key differences will guide you in deciding which method to use and when to use it.
Here’s a head- to-head comparison of differences between aluminum extrusion and traditional manufacturing methods:
| Aluminum Extrusion | Traditional Manufacturing Methods |
| The manufacturing process is streamlined and efficient as it involves pushing a billet through a die to create complex cross-sectional parts. | Traditional manufacturing is not a one-step procedure but is accomplished through multiple steps such as casting, machining, and finishing. It can, therefore, be more complex and time-consuming. |
| With aluminum extrusion, intricate designs featuring different cross-sectional shapes can be created, which allows for design flexibility | The casting process can be limited, allowing only the creation of specific shapes because of the design complexity and customization |
| Aluminum extrusion is the best process for those looking to create consistent and repetitive profiles at a faster rate | Due to the many processing steps involved, traditional manufacturing methods can take quite a long time to complete |
| With aluminum extrusion, little to no material is wasted since the process shapes the aluminum into the precise wanted form | Traditional manufacturing methods can generate more waste, especially during the machining and shaping process |
| Parts produced using aluminum extrusion can maintain their properties as they are exposed to less heat during the process | Parts produced using die casting are subjected to harsh processes that can alter the material properties |
| Extruded parts have a smooth and consistent finish | The surface finish for traditionally manufactured items can vary and may be subjected to further processes to refine their looks. |
| Aluminum extrusion is a perfect method for producing items in high volume thanks to the efficiency of continuous extrusion. | Volume production here can be challenging because it might take longer, and the cost might be high. |
| Aluminum extrusion allows for high precision and tight tolerances in the final product | To achieve tight tolerances, additional machining methods might be needed. |
| The process is pretty straightforward, requiring little effort, and is less expensive | The process changes need a lot of time and are expensive |
| The process is less expensive and hence suitable for short production runs | Suitable for higher production runs |
Conclusion
Both processes have advantages and disadvantages, and the one to use depends on your project specifications. For instance, die casting, despite it being expensive, is cost-effective. On the other hand, you cannot rely on aluminum die casting to produce products in high volumes. To sum up, conduct thorough research to decide on the option that suits you best.
Sunrise Metal,a leading die casting,and aluminum CNC machining manufacturer is here to help you manufacture high-precision and quality parts. Contact us today, and we will sort out all your manufacturing needs.