Custom Aluminum Extrusion Supplier
In manufacturing, custom design elements can be a great way to differentiate a project—but creating these custom designs can get tricky.
When it comes to aluminum extrusion, our in-house engineering team goes way beyond standard options to help develop and fabricate the custom shapes you need for your cutting-edge designs.
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Why Aluminum Is Easy To Love For Extrusions
Aluminum is prized for its high strength-to-weight ratio, which makes it ideal for architectural applications like doors, windows, railings, and canopies. In fact, the material’s many strengths—durability, low maintenance, sustainability, and a multitude of finishing options—make aluminum extrusions a popular choice for a number of industries.
Aluminum can
- Conduct heat rapidly
- Conduct electricity well
- And resist corrosion
It is also easy (and fun) to work with, especially if you need an innovative solution to a custom part. Keep reading to learn what to expect when working on a custom aluminum extrusion project.
Ins and Outs of Aluminum Extrusion
Aluminum extrusion is a process by which an aluminum alloy is forced through an extrusion die with a specific cross-sectional profile. Think of it like squeezing a tube of toothpaste. As force is applied, the material emerges in the shape of the opening.
Extruded shapes can be solid, with no enclosed openings, as in rods or beams. They can also be hollow, like tubes, or semi-hollow, such as a “C” channel. Through extrusion, it’s possible to create a custom solid or hollow metal shape suited precisely to the project’s structural, functional, and aesthetic requirements.
Aluminum is prized for its high formability, making it easy and inexpensive to shape—even into complex geometric shapes. Through fabrication, extrusion can be punched, drilled, or machined to achieve the final dimensions for your custom piece.
Alloys for Extrusions
Extrusions are available in a wide variety of alloys. Our team of engineers bring a thorough understanding of aluminum and its alloys and can help you identify the best option for your specific extrusion project.
We’re well-versed in working with Alloy 6063, the most common alloy used for aluminum extrusion, but we can also work with most alloys in the 6000 series, including 6005, 6005A, 6105, 6101, 6082, and 6061. 6000 Series Alloys, made from magnesium and silicon, are prized for their machinability, weldability, and formability.
Talking Shape
No matter what shape your custom request takes, we can handle it. Here are some of our more common extrusion shapes:
- Round Rod
- Rectangle/Solid Bar
- Square Bar
- Rectangle Tube
- Square Tube
- Schedule Pipe
- Round Tube
- Square Corner
- Structural Angle
- Channel
- Structural Channel
- I-Beam
- Tee
- Hexes
- Z-Bar
Finishing Touches
Aluminum boasts a naturally occurring protective oxide layer, but when additional surface finishing is required for aesthetic or environmental reasons, we offer the following surface treatments.
- Anodizing: Anodizing aluminum is a popular choice for enhancing the durability of metal parts. By creating a protective layer on the surface, anodizing makes it more hard, abrasion-resistant, and corrosion-resistant, making it an excellent option for products that need to stand up to tough environments.
- Chromic Conversion: Non-decorative coatings applied to aluminum parts to achieve a thin, electrically conductive coating that will provide corrosion resistance.
- Wet & Powder Coating: Powder coating forms a strong protective layer over the material to better protect against the effects of salts or chemical substances.
The Federal Group Difference
When you work with the Federal Group, you can count on expert engineering, modern manufacturing, innovative logistics—and proven quality. We are relentlessly committed to manufacturing high-quality, cost-effective, and time-sensitive solutions for our clients. We’re an ISO:9001-certified manufacturing company.
And our process incorporates inspection at every stage of the process. With our in-house quality team, we can perform everything from FAI to PPAP submissions—and everything in between.
Start a Custom Aluminum Extrusion Project Today
The Federal Group is a leading producer of custom extrusions for industries throughout the world. Contact us today to learn how we can collaborate on a custom aluminum extrusion for your next project.
Client Testimonials
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Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
