Custom Aluminum Extrusion Supplier
As a top U.S. aluminum extrusion supplier, The Federal Group provides custom aluminum extrusion services and premium extruded components for consumer products, industrial clients, and more. Our in-house engineering experts turn complex aluminum designs into manufacturable solutions.
Request a QuotePrecision Engineering
Custom designs with tight tolerances of ±0.005 in.
Full-Service Solutions
Extrusion, machining, finishing, and assembly – all under one roof.
Manufacturing at Scale
Extruded aluminum profiles produced in 8 to 50+ foot lengths.
Any Profile, Delivered
Solid, hollow, bars, tubes, and custom profiles.
Serving Diverse Industries
As a U.S.-owned aluminum extrusion manufacturer, The Federal Group USA serves multiple industries. Our expertise as a custom aluminum extrusion supplier ensures fast delivery of high-precision aluminum parts to the construction, medical, manufacturing sectors, and more.
Construction and Infrastructure
In the construction and infrastructure sectors, extruded aluminum profiles are used for everything from framing systems and enclosures to window and door profiles and structural supports. Aluminum’s high strength-to-weight ratio and corrosion resistance make it ideal for long-lasting architectural and infrastructure components.
Medical Equipment
Extruded aluminum is used for lightweight carts, brackets, and frame assemblies in the medical equipment industry. The aluminum extrusions manufactured by TFG support the cleanliness, mobility, and performance required in clinical settings to meet safety and hygiene requirements.
Machinery and Manufacturing
TFG works with machinery and manufacturing equipment suppliers to produce structural frames, protective enclosures, sensor housings, and automation systems. Custom aluminum shapes and profiles improve rigidity, simplify assembly, and offer modular flexibility in industrial and production settings.
Available Materials
As a versatile aluminum extrusion supplier since 1980, The Federal Group delivers a wide range of aluminum including most alloys in the 6000 series, including 6005, 6005A, 6105, 6101, 6082, 6061, and more.
- 6061 Aluminum for Structural Strength: A versatile alloy for durable, load-bearing extrusions across industrial and architectural projects.
- 6063 Aluminum for Smooth Finishes: Ideal for window frames, curtain walls, and applications requiring smooth surface finishing and aesthetic appeal.
- 6005A Aluminum for Strength and Extrudability: A material that balances strength and flexibility for custom profiles that meet tight tolerances.
Extrusion Shapes
- Channels
- Angles
- Beams
- Bars
- Tubes (round, square, rectangular)
- Custom geometries
Extrusion Types
- Solid Profiles: Perfect for structural and industrial applications.
- Hollow Profiles: These offer lightweight strength and versatility for everything from framing to fluid transport.
- Multi-Void Profiles: Ideal for reducing weight while maintaining rigidity in complex or high-performance designs.
- Complex Custom Profiles: Engineered to meet specialized requirements.
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.
Transparent Lead Times
At The Federal Group, we provide honest lead time estimates for prototypes, first runs, and full production. Factors such as profile complexity, quantity, alloy, testing, and secondary operations all influence timing.
Clear, Upfront Pricing
Our quotes outline every cost component, so you know exactly what’s included—no surprises. The Federal Group’s proposals cover tooling, sample delivery, drawing updates, basic inspection, and flexible financing options.
The Federal Group Difference
The Federal Group delivers expert engineering, modern manufacturing, innovative logistics, and proven quality. As an ISO 9001-certified company inspections are built into every stage of the process—from FAI to PPAP submissions and beyond.
Start a Custom Aluminum Extrusion Project Today
Looking for a manufacturer who specializes in the extrusion process? Contact us today to get a free quote.
Client Testimonials
Trustindex verifies that the original source of the review is Google.
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!
