Custom Extrusion Request

Custom Aluminum Extrusions & Profiles

Have an idea for a new custom aluminum extrusion? Looking to refine an existing aluminum profile, improve functionality, or reduce labor costs? Monarch Metal is here to help.

We specialize in turning ideas into efficient, cost-effective solutions through custom aluminum extrusions. Whether you’re developing a new aluminum part or optimizing an existing aluminum extrusion profile, our team supports you through every step, from concept to delivery.

Custom aluminum extrusions are often engineered to minimize the number of parts required, accelerate assembly, and enhance overall value. They’re widely used across many industries for good reason, you’ll find aluminum extruded components everywhere, from everyday household products to heavy industrial machinery.

We offer a variety of surface finishes for aluminum extrusions including mill, clear anodized, black anodized, black powdercoat, and custom powdercoat colors to ensure your product looks and performs exactly as needed. Additionally, to help streamline your manufacturing process, Monarch Metal provides value-added services such as drilling, tapping, punching, and cut-to-length processing, saving you time and effort downstream.

If you have an idea for an aluminum extrusion, just complete our form. We’ll review your information and reach out to schedule a free initial consultation.

Review Our Process & Request a Free Custom Extrusion Quote

  1. Review Your Materials

    Every custom extrusion project begins with understanding your vision, requirements, and application needs. We review sketches, CAD files, reference drawings, dimensions, and project specifications to evaluate feasibility and identify the most effective path forward. This early review process helps establish clear expectations and lays the foundation for a successful extrusion design.

  2. Develop Initial Concepts

    Based on the information provided, our team develops preliminary extrusion concepts tailored to your project goals. Profile shapes, functional requirements, material considerations, and manufacturing possibilities are explored during this phase. These early concepts help visualize how the extrusion may perform while identifying opportunities for efficiency and optimization.

  3. Customer Consultation

    We work directly with you to review concepts, discuss design priorities, and answer technical questions. This collaborative stage helps refine expectations surrounding functionality, tolerances, finishes, assembly requirements, and production goals. Open communication ensures the project remains aligned before moving into detailed engineering and development.

  4. Design & Development of Aluminum Extrusions

    Detailed extrusion profiles and technical documentation are developed to prepare the project for manufacturing. Engineering drawings, dimensions, tolerances, wall thicknesses, and production requirements are refined to ensure both performance and manufacturability. This stage transforms conceptual ideas into production-ready extrusion designs.

  5. Prototyping

    Prototype samples can be produced to evaluate fit, function, and overall performance before full manufacturing begins. Testing prototypes in a real-world environment allows designs to be validated and refined prior to tooling investment and production. This process helps reduce uncertainty while improving confidence in the final product.

  6. Cost Estimate

    A detailed project quote is prepared outlining tooling, extrusion production, finishing, fabrication, and related costs. Material requirements, production quantities, and manufacturing considerations are carefully evaluated to provide accurate pricing. This stage gives customers a clear understanding of project scope, timelines, and investment requirements.

  7. Tooling & Production

    Once designs and pricing are approved, tooling is ordered and production begins. Extrusion dies are manufactured to exact specifications before aluminum profiles move into the extrusion process. Post-extrusion fabrication including finishing, cutting, and punching is performed as needed before a final quality review ensures every part meets project requirements and performance standards.

  8. Delivery

    Finished aluminum extrusions are carefully packaged and prepared for shipment to your facility or job site. Products arrive ready for fabrication, assembly, installation, or distribution depending on project requirements. From initial review through final delivery, the process is designed to provide a streamlined and reliable customer experience.

Name(Required)
Please provide a brief description of your custom extrusion. Typical Uses, Critical Features, and Critical Dimensions
Please select an alloy for your custom extrusion. If you're not sure of the optimal material, please choose "I'm not sure."
Desired Finish or Finishes
Value-Added Services
Monarch Metal can provide a variety of value-added services.
Please give an estimate of the annual usage of your custom extrusion(s)
Please attach any relevant files for your custom extrusion.
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Max. file size: 2 GB, Max. files: 5.

    Frequently Asked Questions

    What are custom aluminum extrusions?

    Custom aluminum extrusions are precision-engineered profiles created by forcing heated aluminum billet through a machined die to achieve a specific cross-section. Unlike off-the-shelf shapes, custom aluminum extrusion profiles let you integrate functional features directly into the part, reduce component counts, and achieve a precise fit for your application.

    What are the benefits of using custom aluminum extrusions?

    Key advantages of custom aluminum extrusions include reduced assembly complexity (fewer separate parts), time and labor savings via built-in features and cut-to-length processing, performance tailored to your needs (strength, durability, tolerance control), and a wide range of finishes such as mill, clear anodized, black anodized, and custom powder coat colors.

    What should I consider before starting a custom aluminum extrusion project?

    When planning custom aluminum extrusions, account for die and tooling costs and align expected volumes to amortize them effectively. Select the aluminum alloy and finish appropriate for the environment, define tolerances carefully, and use prototypes to validate fit and function before committing to production. Close collaboration on manufacturability and cost drivers helps ensure an optimal, cost-effective aluminum extrusion design.

    What is the process for developing a custom extrusion?

    The process for creating custom aluminum extrusions typically includes: reviewing your sketches or CAD files, collaborative concept development, engineering documentation, and prototyping (including 3D-printed samples if needed). We provide cost estimates for your aluminum extrusion profiles (including tooling) prior to production, then proceed with die manufacture, aluminum extrusion, finishing, and delivery. Value-added operations such as drilling, tapping, punching, and cut-to-length are available to streamline installation.

    What aluminum alloys are commonly used for custom extrusions?

    Most custom aluminum extrusions use alloys from the 6000-series; such as 6063 and 6061, because they offer a strong balance of strength, corrosion resistance, and surface finish quality. Other alloys can be selected if specific mechanical properties or finishing needs are required. Choosing the right alloy is key to meeting both structural and appearance goals.

    How do I choose the right finish for my custom aluminum extrusion?

    Finishing options for custom aluminum extrusions include mill finish, clear or color anodizing, and a wide range of powder-coat colors. The best choice depends on the application’s durability requirements, aesthetic goals, and environmental exposure. Our team can recommend finishes that maximize performance and appearance for your specific extrusion.

    Can custom aluminum extrusions reduce overall assembly costs?

    Yes. By incorporating multiple functions, such as channels, grooves, or mounting features, into a single custom aluminum extrusion, you can reduce part counts, simplify assembly, and cut labor costs. Fewer separate components also improve consistency and reduce potential points of failure in the finished product.

    Are there minimum order quantities for custom aluminum extrusions?

    Yes. Minimum order quantities for custom aluminum extrusions depend on the profile’s complexity, the chosen alloy, and any required finishing processes.

    Our typical minimum order is 1,000 lbs, but we can often accommodate projects as low as 500 lbs. Even if a design comes in slightly under the 500-lb mark, we’re happy to provide a quote to explore your options.

    We’ll recommend the most cost-efficient quantity based on your design specifications and production goals to ensure you get the best value for your custom aluminum extrusion project.