Automotive & EV | Dajcor Aluminum

Automotive & EV Applications

Dajcor Aluminum supports automotive and EV manufacturers with lightweight aluminum extrusion solutions engineered for transportation performance and scalable production.

Automotive and EV programmes bring the tightest tolerances and the highest volumes we handle, and they bring them together. A section has to be right and then stay right across hundreds of thousands of parts.

Side view of a passenger car — Weight taken out of the structure shows up as range, payload or fuel efficiency.

Common applications we support

Where our profiles typically end up in this market.

EV battery enclosure components

Battery enclosure sections — trays, frames and sealing surfaces for EV packs.

Thermal management profiles

Cooling plates and heat-transfer sections where the extrusion carries the thermal load.

Structural support systems

Structural support members where weight reduction is a programme target.

Charging infrastructure components

Housings, posts and mounting sections for charging equipment, finished for outdoor service.

Interior trim profiles

Visible trim and panel-retention sections, anodized or painted to match the interior.

Transportation assemblies

Machined and fabricated transportation sub-assemblies delivered ready to fit.

Weight, thermal load and volume at once

Electrification changed what these programmes ask for. Battery enclosures need structural sections that also manage heat and seal reliably, so the profile is simultaneously a structural member, a thermal path and a sealing surface. Those requirements are best resolved together, before the die is cut.

Volume then makes repeatability the whole problem. Multi-axis machining puts features on several planes in one setup, which removes the stack-up error that comes from re-fixturing, and in-process inspection holds the dimensions across the run.

A battery tray is a structural member, a thermal path and a sealing surface in one extrusion.

Materials and finishes

Profiles for every industry we serve are extruded from 6000-series alloys and finished in-house. The right combination depends on the loads, the environment and how visible the part is.

6063 and 6060: General-purpose and detailed sections with excellent surface quality — the usual choice where the part is seen.
6061 and 6082: Higher-strength structural alloys for load-bearing and safety-critical sections.
6005 / 6005A and 6463: Structural sections needing more strength than 6063, and bright architectural trim.
Anodized finishes: Clear satin and etched, electrolytic colour and chemically bright, up to 27 ft in length.
Painted finishes: Durable indoor and outdoor coatings with consistent colour matching across runs.
Mechanical finishes: Buffing, brushing and deburring where a specific surface texture is required.

Key manufacturing capabilities

Dajcor Aluminum delivers engineered aluminum extrusion solutions backed by technical expertise, responsive service, and dependable North American manufacturing capabilities.

Custom aluminum extrusions in 6000-series alloys
Precision CNC machining and fabrication
In-house anodizing and painted finishes
Extrusion lengths up to approximately 28 feet
Prototype through production manufacturing support
Canadian and U.S. manufacturing capabilities

Key advantages

Vertically integrated manufacturingExtrusion, machining, fabrication and finishing run in our own plants, so parts are not crated and shipped between vendors after every operation.

Precision-machined aluminum solutionsComponents arrive machined to drawing and ready to assemble, rather than as stock lengths that still need work.

Reduced supply chain complexityOne purchase order, one production schedule, and one supplier accountable for the finished component.

Reliable lead times and scalable capacityFour presses across two countries, with roughly two-week lead times on mill-finish profiles running existing tooling.

Capabilities behind this work

The in-house processes this market draws on most.

Design Support Engineering & design support built for performance, manufacturability & cost efficiency See the capability → Machining Precision CNC machining built for accuracy, consistency & production efficiency See the capability → Extrusion Manufacturing the most complex of extruded products. See the capability →

Common questions

Answers to the questions that come up most often at the quoting stage.

Can aluminum extrusions replace steel components?

In many applications, aluminum extrusions can successfully replace steel components while offering several advantages.

Aluminum provides an excellent strength-to-weight ratio, meaning it can deliver structural performance while significantly reducing overall weight. This can improve efficiency in applications such as automotive, transportation, industrial equipment, and infrastructure systems.

Extrusion also allows engineers to integrate multiple design features—such as ribs, channels, and hollow sections—into a single profile. This can reduce part counts, simplify assembly, and lower overall manufacturing costs.

When evaluating a steel-to-aluminum conversion, factors such as load requirements, corrosion resistance, finishing needs, and fabrication processes should be considered. Our team works with customers during the design stage to help determine whether an aluminum extrusion is a suitable alternative for their application.

What tolerances can be achieved with aluminum extrusions?

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.

What industries does Dajcor serve?

Dajcor Aluminum supplies custom aluminum extrusions to a wide range of industries that require lightweight, durable, and high-performance components. Our extrusions are used in applications across sectors such as:

Automotive and transportation
Electric vehicle (EV) components and electrification infrastructure
Defense and aerospace support applications
Construction and architectural systems
Industrial equipment and automation
Renewable energy systems
Lighting and electrical systems
Consumer and commercial products

By working closely with engineers and manufacturers, Dajcor helps develop extrusion solutions that improve product performance, reduce component weight, and simplify manufacturing and assembly.

Aluminum for Automotive