Extrusion
Manufacturing the most complex of extruded products.
Custom Aluminum Extrusion Solutions Built for Performance, Precision and Scale
Supporting manufacturers across North America with high-quality aluminum extrusions designed for strength, consistency, and efficient production.
At Dajcor Aluminum, extrusion is at the core of what we do.
We specialize in producing custom aluminum profiles that meet demanding performance, tolerance, and production requirements. Working closely with your team, we develop solutions that support both design intent and manufacturing efficiency, from prototype through full-scale production.
Four presses across two plants give us a range of container sizes rather than one compromise, so a small detailed profile and a large structural section can each run on suitable equipment instead of whatever happens to be available.
What We Extrude
- Solid, hollow, and semi-hollow profiles
- Structural and load-bearing components
- Thin-wall and lightweight designs
- Multi-feature and integrated profiles
- High-visual and cosmetic surfaces
- Custom shapes designed for downstream machining and assembly
Equipment and specifications
Press selection is driven by the profile's circumscribing circle, its wall thickness and the volume behind it. These are the envelopes we work within.
| Press | Force | Count |
|---|---|---|
| 9″ container | 2,800 tons | Two presses |
| 8″ container | 2,800 tons | One press |
| 7″ container | 1,650 tons | One press |
| Parameter | Capability |
|---|---|
| Maximum circumscribing circle diameter (CCD) | Approximately 11″ |
| Maximum extrusion length | Up to 28 ft |
| Profile types | Solid, semi-hollow and multi-hollow |
| Dimensional tolerances | Aluminum Association standards |
| Typical minimum order | 500–1,000 kg, depending on profile weight |
| Alloy | Character | Typical use |
|---|---|---|
| 6063 | Excellent surface finish | Architectural and general-purpose profiles |
| 6463 | Enhanced finish and anodizing quality | Bright and decorative architectural trim |
| 6061 | Higher strength | Structural and industrial components |
| 6082 | High mechanical strength | Load-bearing structural profiles |
| 6005 / 6005A | Stronger than 6063 | Structural profiles needing extra strength |
| 6060 | Good extrudability and surface quality | Detailed and thin-wall profiles |
Performance features
What the process is designed to deliver, and why it matters downstream.
Where We Add Value
We don’t just extrude. We help improve your product.
Our design support team works with your engineers to:
- Optimize profiles for manufacturability
- Reduce post-extrusion machining and fabrication costs
- Improve performance while simplifying production
Why Dajcor
Dajcor has run as a one-stop, dual-source supplier since 2010, with plants in Chatham, Ontario and Chavies, Kentucky. Removing subcontractors from the chain is what shortens lead times and keeps handling marks and freight costs down.
- Reliable North American supply chain
- Short, predictable lead times
- Consistent quality across production volumes
- Integrated with machining, fabrication, and finishing
- Responsive support from prototype through production
From Design to Production
How a project moves from first conversation to delivered parts.
- Profile design and feasibility
- The section is reviewed for extrudability and matched to a press, an alloy and a tolerance strategy.
- Die development
- The die is designed and built for the profile, accounting for metal flow and expected correction.
- Sampling and approval
- First articles are extruded and measured, and the die is corrected until the section holds.
- Production scaling
- The profile moves into scheduled production, with quality checks across the run.
- Secondary processing and finishing
- Machining, fabrication and finishing are sequenced in-house behind extrusion.
Ideal Applications
This capability shows up across every market we serve. A few of the most common:
Also suited to
- Architectural and building systems
- Automotive and EV
- Industrial automation
- Defence and infrastructure
- Marine and recreational
- Medical and cleanroom systems
Common questions
Answers to the questions that come up most often at the quoting stage.
Dajcor Aluminum operates multiple extrusion presses, including two 9-inch 2800-ton presses, one 8-inch 2800-ton press, and one 7-inch 1650-ton press. These presses allow us to manufacture a wide range of aluminum profiles for structural, architectural, automotive, and industrial applications.
Our extrusion capabilities support profiles with a circumscribing circle diameter (CCD) of up to approximately 11 inches, with extrusion lengths of up to 28 feet, depending on the profile design and alloy.
During the design and quoting stage, our engineering team reviews each profile to confirm compatibility with our press capabilities and to ensure the extrusion can be manufactured efficiently while meeting dimensional and performance requirements.
Early collaboration helps optimize profile design for manufacturability, cost efficiency, and long-term production success.
Dajcor Aluminum primarily extrudes alloys from the 6000 series, which are widely used for structural and industrial applications due to their excellent strength, corrosion resistance, and machinability.
Common extrusion alloys include:
- 6063 – Widely used for architectural and general-purpose applications with excellent surface finish
- 6463 – An architectural alloy that provides enhanced surface finish and anodizing quality
- 6061 – A higher-strength alloy commonly used in structural and industrial components
- 6082 – A strong structural alloy often used where higher mechanical strength is required
- 6005 / 6005A – Suitable for structural applications requiring higher strength than 6063
- 6060 – An alloy commonly used for profiles requiring good extrudability and surface quality
Our team works closely with customers to select the most appropriate alloy based on the application’s strength requirements, finishing needs, and fabrication processes.
If your project requires a specific alloy or performance characteristic, our engineering team can help determine the best material for your extrusion profile.
Aluminum extrusion tolerances depend on several factors, including the size and complexity of the profile, wall thickness, alloy selection, and the circumscribing circle diameter (CCD) of the extrusion. Industry standard tolerances are typically based on guidelines published by the Aluminum Association, which define achievable dimensional accuracy for solid, hollow, and semi-hollow profiles.
With Dajcor’s 7", 8" and 9-inch extrusion presses, we are able to produce a wide range of aluminum profiles that meet standard Aluminum Association tolerances across many applications. During the design and quoting stage, our team reviews each profile to confirm achievable tolerances based on the specific geometry and manufacturing requirements.
Working collaboratively during the design phase helps ensure the extrusion profile is optimized for manufacturability while maintaining the dimensional precision required for the application.
Looking to develop a custom extrusion or improve an existing profile?
Let’s build a solution that supports your performance, cost, and production goals.
Request a QuoteOther services we offer
Your Industry. Our Capability. One partner for extrusion, machining, fabrication and finishing.
Machining
Precision CNC machining built for accuracy, consistency & production efficiency
Fabrication
Custom fabrication solutions built for integration, efficiency & scale
Design Support
Engineering & design support built for performance, manufacturability & cost efficiency
Finishing
Custom finishing with our automated anodize line.