An Introduction to Aluminum Fabrication


Aluminum is one of the most widely-used metals throughout various industries because, when fabricated the right way, it offers a wide range of benefits. Before enjoying the benefits of such a versatile metal, it is important to understand the process of aluminum fabrication and its benefits.


Aluminum is malleable, which makes it highly adaptable to shaping and extension. Aluminum fabrication itself is the process of cutting, shaping, and extruding aluminum into a finished product. As a metal, aluminum offers a range of different advantages that make it a great choice for metal fabrication projects, such as:

  • Lightweight – aluminum weighs a third less than stainless steel while offering a higher strength-to-weight ratio.
  • Easy to work with – aluminum is soft, corrosion-resistant, recyclable, and non-toxic.
  • Cost-effective – aluminum is affordable, making it ideal for both small-scale residential and large-scale industrial applications.
  • Non-magnetic – aluminum can be used in electrical applications with magnet-sensitive system components.
  • Customizability – aluminum can be fabricated into a wide range of different shapes and styles with varying finishes.


Similar to other types of metal, aluminum can be fabricated using a variety of different techniques; with some methods working better than others depending on the user’s desired objective. Some of the most popular aluminum fabrication techniques include:

  • Extrusions – forcing a piece of aluminum through or around a die to conform the aluminum to the die’s shape and size. Extrusions can be done either hot (where the metal is heated) or cold (where the metal is at room temperature).
  • Drawing – to stretch the aluminum by pulling it through a tapered die.
  • Forming – pressing all or part of the aluminum into the desired end product.
  • Castings – pouring liquid aluminum into a mold or die.
  • Forging – beating or compressing the aluminum into the desired shape, this method is best for applications where the end results must be incredibly durable.
  • Machining – sculpting by removing aluminum from the sheet.
  • Waterjet cutting – using a high-pressure water spray with abrasives to cut the aluminum.
  • MIG and TIG welding – melting a metal thread to bind two pieces of aluminum together.
  • Adhesive bonding – using specific adhesives to bond two pieces of aluminum together.


Aluminum’s properties make it ideal for uses that vary widely across industrial, commercial, and consumer applications, including Aerospace, which uses aluminum’s weight-to-strength ratio and corrosion resistance for wings, fuselages, and parts. Packaging, including cans and foil, which rely on aluminum’s easy workability, softness, and durability. Automotive applications, use aluminum to absorb crash forces. It is also used to make car bodies and components lighter and therefore more fuel-efficient. Construction, where aluminum acts both as decoration and as structural material thanks to its energy efficiency and sustainability. Electronics and electrical applications. Power grids use aluminum wiring and conductors in power grids. Consumer electronics like refrigerators and laptops use aluminum due to its thermal abilities, lightweight, and structural integrity.


If you would like to learn more about what aluminum fabrication is, or if you are interested in our aluminum fabrication services, please contact us, Alusite has extensive experience in aluminum fabrication.