Aluminum Extrusions, Roll Forming & Stampings

Zauderer Associates has in depth knowledge and years of experience with aluminum extrusions, plastic extrusions and metal stampings. We help to provide all engineering support and design assistance for your projects, no matter how simple or complicated.

Our partners have a large selection of parts and the ability and tools to create custom parts as needed. The quality of all parts are excellent and customer satisfaction is the priority. Or partners offer full-service capabilities so your entire project can be completed with one order from design and engineering assistance to extruding / stamping to finishing and packaging.

Some Of The Industries We Serve:

Aerospace, Agriculture, Appliance, Boating & Marine, Construction, Electrical, Furniture, HVAC & Air Filtration, Military & Defense,
Power & Renewable Energy, Transportation

Aluminum Extrusions

Roll Forming

Stampings

Metal Processing

Aluminum Extrusions, Roll Forming & Stampings

Aluminum Extrusions

What are Aluminum Extrusions used for?
Since there are endless design possibilities and potential with aluminum extrusions, they can be found in almost every industry and in a large number of end products. For example, aluminum extrusions are used in transportation industries, including boats, automobiles, trailers and other recreational vehicles. Aluminum extrusions are also used in medical equipment, furniture, ladders, windows, doors, heating and cooling devices on computers and other electronics as well as many other products.
How much weight can extruded aluminum hold?
Aluminum extrusion are very strong and is one of their benefits in the manufacturing process. The strength of extruded aluminum depends on multiple factors including the addition of alloys, the general shape, and the size of the extrusion.
Is cast aluminum stronger than extruded aluminum?
It really depends on the actual mold and product. In general, since cast aluminum is solid and formed in a mold and extruded aluminum / aluminum extrusions are sometimes hollow or semi-hollow (although they can also be solid) then cast aluminum is sometimes thought to be stronger. However, aluminum extrusions are very strong, especially for its weight.
What is the difference between cast aluminum and extruded aluminum?
Cast aluminum is different than extruded aluminum and are two different manufacturing options when making a product out of aluminum. Die cast aluminum is where molten aluminum metal is injected into a die mold and then it cools within the shape. Extruded aluminum products are made by forcing heated aluminum through a die to create a specific cross-sectional profile.

There are many benefits of aluminum extrusions including that they tend to be less expensive than casting molds, have a very smooth finishing surface, highly adaptable and customizable for a variety of shapes, and are very strong but still lightweight.

What shapes are available with aluminum extrusions?
Shapes of aluminum extrusions generally fall into three categories: solid, hollow, or semi-hollow. In each category, we can manufacturer from simple to very complex and customized shapes. We can offer access to over 2,500 standard shapes ranging from square tubes, round tubes, flat bars, channels, and Z-bars and many more. However, we also excel at creating the custom aluminum extrusion shape that your product requires.
What finishes are available for aluminum extrusions?

We offer many options of both painted or anodized finishes to complete your standard or customized aluminum extrusion:

  • Powder Paint
  • Wet Paint
  • Clear or Color Anodizing
  • Architectural Paints
  • Architectural Anodizing
  • Teflon
  • Buffering
  • Sanding
  • Deburring
  • Brushing
What alloys does the extruder provide?

Determining the correct alloys to use in an aluminum extrusion is very important as it can alter the strength, durability, corrosion resistance, and appearance of the finished aluminum extrusion.

6000 series are alloyed with magnesium and silicon. They are easy to machine, are weldable, and can be precipitation hardened, but not to the high strengths that 2000 and 7000 can reach. 6061 alloy is one of the most used general-purpose aluminum alloys.  Below is a list of alloys available:

How wide and long an extrusion can the extruder provide?

The shape of the aluminum extrusion determines the exact size that can be fabricated; however, a general range is from ½ inch up to 25 feet.

Does the extruder provide mill, anodized and painted finishes?

Yes, the extruder can provide mill, anodized and painted finishes on the custom and standard aluminum extrusions.

What fabrication can be added to the extrusions other than cut-to-length?

There are many fabrication services available including complex bending, Mig & Tig welding, precise hold punching, milling & nothing, drilling & tapping, mechanical & welded assemblies and all types of mechanical finishes.

What is the ballpark cost of an extrusion die?

The cost of an extrusion die varies greatly based upon the complexity.  Our manufacturer has access to have 2,500 standard shapes available, so it is possible that we already have the die ready to go.  However, we offer the ability to create customized shapes.  The cost of a customized extrusion die will depend on the size and intricacy of the extrusion product.

How do you create a customized aluminum extrusion?

There are many steps in the production cycle of an aluminum extrusion.  First, you must work with the design team and engineers to create the right cross section needed for your product.  The extrusion die is then created or prepared to move through the extrusion press.  An aluminum billet, which is what determines the size of the aluminum extrusion, is preheated and transferred to the extrusion press.  A ram pushing the billet material into the container where the extrusion press is, and the extruded material emerges through the die.  The extrusion is cooled and then cut to the correct length.  Next the aluminum extrusion can get various finishes for appearance purposes and/or protection against environmental factors and corrosion.

There are many steps in creating a customized aluminum extrusion and Zauderer Associates, Inc. can assist you throughout the entire aluminum extrusion production process including the design and engineering, extruding, finishing, fabricating and can help ensure timely delivery. 

Roll Forming

What is roll forming used for?

Roll forming is the perfect manufacturing process when many of the same shape product is needed.  It is also great for products with long profiles including fencing, door and window hardware and drawer slides.  Roll forming products have tight tolerances and high-quality finishes.  Roll forming is a great manufacturing process when custom components are needed.

What is the roll forming process?

Roll forming is the process of incrementally bending strips of metal through using a placement of precise rollers through a roll forming machine.  A roll forming machine will have multiple stands and in each stage the material will be progressively shaped.  After the shape is created there are a variety of secondary operations that can be performed to the metal including bending, embossing, flattening, hand welding, in-line punching, mitering, notching, piercing, punching, stamping, tabbing, tapping, and minor assembly.  Additionally, there are a variety of finishes available including anodized, chrome plated, polished, powder coated, pre-coated, pre-finished, pre-painted, pre-plated and zinc plated.

What are the benefits of roll forming?

Benefits of roll forming include cost savings especially when producing large quantities, ability to customize and shape products regardless of metal and type of finish, consistent product, and limited scrap.

What materials can the roll former provide?

Roll forming is a manufacturing process that can use virtually any metal and their alloys, including materials that already have finishes on them.  Materials available include aluminum, brass, bronze, carbon steel, copper, stainless steel, steel, cold rolled steel, galvanized steel, high strength steel, hot rolled steel, tin plated steel and vinyl clad metals.

What thickness of material can the roll former roll?

Thickness of roll formed parts can range from 0.018 inch to 0.1644 inch – up to 8 gauge material thicknesses.

What is the maximum length of a roll formed part?

Very long parts, up to 45 feet long can be roll formed.  Additionally, very small parts around 12” can also be roll formed.

What additional fabrication services can the roll former provide?

After the shape is created there are a variety of secondary operations that can be performed to the metal including bending, embossing, flattening, hand welding, in-line punching, mitering, notching, piercing, punching, stamping, tabbing, tapping, and minor assembly.  Additionally, there are a variety of finishes available including anodized, chrome plated, polished, powder coated, pre-coated, pre-finished, pre-painted, pre-plated and zinc plated.

What would be a typical cost for the roll forming tooling?

This varies by the complexity of the shape and number of bends to achieve the final design.  Cost for tooling is dependent on how many stations will be needed to bring the flat starting metal coil into a final shape and design.  Increase the number of stations and the cost increases.  In general, a roll forming tool can run between $15,000 – $100,000.  In most cases, roll forming is best suited for high volume applications due to the upfront tooling costs.

Stampings (Metal Pressing and Metal Stamping)

What are the 4 types of metal stamping?

There are generally thought to be four types of stamping methods.  The chosen method is dependent upon the outcome desired and specified by the engineer:

  1. Progressive die stamping
  2. Transfer die stamping
  3. Four Slide Stamping
  4. Fine blanking
What types of stamping presses are available?

There are three main types of metal stamping presses:

  1. Mechanical stamping presses
  2. Hydraulic stamping presses
  3. Mechanical servo stamping presses
What are the types of metal stamping dies?

Metal stamping dies generally fall into two primary groups:

  1. Single-station dies
  2. Multi-station dies
What are metal stampings used for? (Industries / examples)

Due to the versatility of metal stamping, these products can be found in various industries and products including automotive, aerospace, agriculture, appliances, construction, furniture, electronics, and transportation.

What is the difference between stamping and pressing?

Metal pressing and metal stamping are essentially interchangeable terms for a very similar manufacturing process.

What are the advantages of metal stamping?

One of the biggest advantages of metal stamping is that it has a high degree of accuracy.  Complex and customized designs can be created rather easily with a die and can be repeated with precision.  It is also an inexpensive manufacturing method especially when manufacturing large quantities.

What metal gauge is best for metal stamping?

The metal gauge that is best for metal stamping depends on the type of press used.  Thin metals in the .005” range or lower can be stamped on low tonnage, high speed presses such as Bruderer Presses.  Thicker gauge metals can be stamped on larger 50 ton – 750 ton presses. 

What is the metal stamping process?

A flat piece of metal is transformed into a desired shape by using a die.  Metal stamping machines can punch and bend metals into complicated shapes with a high degree of accuracy.  The hardest part of the process is working with engineers to create the customized die needed for your product.  Once the die has been created, the metal stamping process can be repeated and manufactured easily using highly technical and sophisticated stamping machines.

What materials can be stamped?

Common materials available include aluminum, brass, bronze, carbon steel, copper, stainless steel, steel, cold rolled steel, galvanized steel, high strength steel, hot rolled steel and tin plated steel.

What thickness of metal stampings can be provided?

Most thicknesses can be stamped.  It depends on the tonnage of the press.

What additional fabrication services can be offered?

CNC machining. Bending, embossing, flattening, hand welding, in-line punching, mitering, notching, piercing, punching, tabbing, tapping, and minor assembly. 

What is the typical cost for a stamping die?

Depending on complexity of the stamping, a typical cost for a customized stamping dies can range from $2,500 to $50,000.

What are the typical lead times for stampings?

The lead time for metal stampings typically depends on the complexity of the stamping.  However, in general a good time frame is between 8 – 20 weeks. 

Is there a minimum run quantity for stampings?

Typically, a good range annually is between 25,000 pieces to 250,000 pieces.

Laser Cutting

What is the typical cost of laser cutting?

There is typically a set up charge with laser cutting and then the price is dependent on how long it takes to laser cut the part.  If a CAD drawing can be supplied, sometimes the set up charge can be waived.

What are the advantages of laser cutting?

Laser cutting offers a high degree of precision, clean edges, short lead times, repeatable process for large volumes, and an automated manufacturing process.

What materials are available for laser cutting?

Laser cutting can be used with a variety of metals.  Some commonly used materials for laser cutting include aluminum, brass, stainless steel, and low-carbon steel.  Environmental factors, decorative applications, durability, and longevity needs all play a factor into what type of material should be used.

What are the specifications available for laser cutting?
  • Cutting Length: Up to 10’
  • Cutting Width: Up to 5’
  • Accuracy: .002”
  • Low-Carbon Steel (Mild Steel) Thickness: Up to .5”
  • Stainless Steel Cutting Thickness: Up to .50”
  • Aluminum Cutting Thickness: Up to .375”

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