Choosing the Right Aluminium Extrusion for Automotive Manufacturing

Aluminium extrusions are central to modern automotive engineering, but getting the specification wrong can delay production, introduce compliance risks, and inflate the total cost of ownership. This blog breaks down the technical criteria engineers need to consider when selecting aluminium profiles, helping you avoid common missteps and drive better design outcomes from the start.

In the automotive industry, vehicles roll off the production line every minute thanks to a complex supply chain that ensures that all components are available the moment it is needed.

Aluminium extrusions play a critical role in automotive production, but not all extrusions are created equal. The wrong choice can compromise structural performance, delay production, and lead to spiralling hidden costs.

For engineering teams and those in procurement, finding the right aluminium extrusion is not only a critical operational choice but an economic one too.

We’ll help you with that choice in this blog by explaining the importance of extrusions and the performance criteria you need to measure your selection against. 

Want to work with a solutions provider that specialises in the automotive industry? Learn more about BCW’s aluminium machining and assembly services today.

 

Why Aluminium Extrusions Are the Backbone of Lightweight Automotive Design

Before we explore how to make the right selection, it’s worth understanding why aluminium extrusions have become fundamental in today’s automotive engineering industry.

Not only are they lightweight, but aluminium extrusions are essential in the continued shift to lightweight automotive components across EV and ICE platforms. Their reduced weight provides the further benefit of reducing emissions and enhancing fuel economy.

Manufacturers, for years, had to juggle multi-part assemblies of heavier materials that created challenges for engineering teams. 

Aluminium extrusion has been a game-changer when it comes to keeping those inside vehicles safe and alive. Many manufacturers now leverage extrusion to optimise the structure and materials of a vehicle’s chassis so that, should a crash happen, the energy generated is better absorbed and dissipated through areas of the vehicle where drivers and operators aren’t.

The reliance on aluminium and extrusion also comes from its sustainability properties. Whether it is new legislation forcing the industry to think more about their environmental impact or the growing societal shift around sustainability, automotive manufacturers have a solution to both in the form of aluminium, thanks to its infinite recyclability and lower energy consumption.

But not all aluminium profiles are created equal. The right extrusion must meet very specific engineering and performance demands. Here’s what to consider.

 

How to Evaluate Aluminium Extrusions: 5 Performance Criteria that Matter

The right profile can have huge effects on the performance and durability of your vehicles. And while it is positive that there are so many options available, picking the right one can feel daunting.

Selecting the right automotive aluminium profile depends on factors like strength, formability, and tolerance requirements.

Typically, there are five things to consider each time you’re selecting a profile. Each profile will be different, and there may be further criteria to consider, but these five are a good starting point.

 

1. Structural load requirements 

Depending on the area or type of the vehicle, you may need a particular alloy. Determining your load requirements is an essential first step. If it needs to withstand heavy loads, then an alloy with a higher strength will be needed, typically a high Grade 6000 series, or even 7000 series for greater strength. For products which are more complex and require greater degrees of formability, it would be sensible to opt for lighter allowances, such as the lower grades in the 6000 series range..

 

2. Thermal conductivity 

One of the many reasons aluminium profiles are so widely used is their high thermal conductivity, which allows them to transfer heat efficiently. 

For battery enclosures and electric vehicles, aluminium’s ability to dissipate heat generated by the cells, motors and other components is a significant asset. 

 

3. Compatibility with joining methods 

Aluminium extrusion is extremely versatile, and a wide range of joining methods can be applied to the final product. When choosing a profile, consider the design and the joining needs once it is designed. Think about the expected applications of the profile, whether it needs to be assembled or reassembled, how modular it is, and what level of versatility you need.

 

4. Surface treatment needs

What is going to happen to the surface of the profile once it is manufactured? Consider the properties it needs to have based on its final intended application. Treating the surface creates a desired finish, and anodising and powder coating can protect the aluminium from corrosion and environmental factors such as moisture. 

 

5. Traceability and regulatory compliance 

The automotive industry has strict regulatory requirements to ensure quality remains to an agreed standard and defects can be identified and resolved early. When evaluating profiles, full traceability is needed not just for compliance but for consistent performance in:

• IATF 16949 (automotive quality) 

• ISO 14001 (environmental management)

 

BCW Engineering’s extrusion and machining processes are built around IATF 16949 and ISO 14001 standards, with full digital QA traceability from billet to final part.

 

 

How to Assess Aluminium Extrusion Suppliers in the Automotive Sector

When assessing which extrusion supplier to work with, it's important to consider experience, capacity for production, and quality assurance processes. As an automotive manufacturer, you need to know that your supplier can meet the specifications of your products from day one.

 

Ability to support consistent, technical and high-volume manufacturing

The first thing to consider is whether the intended supplier can achieve your technical requirements and capacity demands. Choose an automotive extrusion supplier with a proven record in not only technical but also volume delivery and component reliability.

 

Vertical integration of infrastructure

Working with a supplier that offers a vertically integrated solution means they’re able to manage the entire supply chain, offering CNC machining, assembly, and treatments, reducing your need to find multiple suppliers for separate processes. BCW’s in-house capability spans aluminium extrusion machining, CNC, surface treatments, and assembly, which reduces multiple touch points and complexity for global supply teams.

 

Tier 1 and OEM approvals

Assess suppliers on factors such as traceability, quality of materials, and sustainability. Verify their ability to meet OEM specifications, assess past performance, and ask to see real-world case studies.

 

In-house DFM support 

Inquire about their experience with Design for Manufacturing (DFM) principles that help to reduce risk and streamline development. Suppliers who understand DFM can help eliminate issues before production even begins. At BCW Engineering, DFM is not an add-on; it’s integrated from concept to production, helping our OEM and Tier 1 customers avoid late-stage rework and shorten lead times.

 

Full process traceability

Full traceability means each part is tracked and verified. To ensure consistency and quality, you need full transparency of every part. Processes such as digital part marking and QA systems with plant diagnostics de-risk your supply chain and help to find root cause problems early.

 

Design for Manufacturability (DFM): Reducing Risk with Early Engineering Input

DFM is a beneficial engineering approach whose aim is to design products for ease of manufacture and cost-effective 

 

This proactivity early in the design process means there is a de-escalation of risk and a reduction in redesign costs, leading to a quicker route to production at the most cost effective pricing. It is an essential practice for anyone involved in product and automotive design.

 

In automotive manufacturing, DFM enables the consolidation of complex multi-part assemblies into single aluminium extrusions. This streamlines assembly on the production line, accelerates manufacturing, and enhances structural integrity.

 

In extruded profiles, you can achieve uniform wall thickness to avoid stress hotspots and warping during cooling. Simplified machining and forming can also be achieved by rounding internal corners and minimising the risk of cracking or fatigue once a load is applied.

 

5 Common Pitfalls in Aluminium Sourcing – and How to Avoid Them

Sourcing the right aluminium supplier for extrusion is an important step, and knowing what to avoid is just as important as knowing what to look for. Knowing these common pitfalls can help you avoid costly, long-term errors.

 

1. Overlooking total cost of ownership: Sourcing aluminium is not just about paying for the raw materials; this ignores the total cost associated with the entire value chain. Overlooking process waste, rework, or transport costs often undermines seemingly cost-effective aluminium solutions.

2. Failing to factor in issues: Aluminium supply chains feature several stakeholders, any one of whom could have issues which impact you. Scrap rates, late deliveries, manufacturing location and quality issues are all things to consider.

3. Inflexible suppliers: As your need for extrusion grows, you need to be able to work with suppliers that can scale up or adapt to changes.

4. Sourcing from outside the UK or EU: Sourcing aluminium outside of the UK or EU raises compliance concerns with the EU’s Carbon Border Adjustments Mechanism. Logistics around declarations need to be factored in, as do the potential financial impacts.

5. No contingency planning: Not having a plan in place in case something goes wrong, such as missed deadlines or a failed Production Part Approval Process, can cause a host of problems.

 

With these pitfalls in mind, what exactly should you expect from a supplier who truly understands the automotive industry?

 

What a High-Quality Automotive Aluminium Supplier Should Offer

At their core, aluminium suppliers should use reliable materials, extrude them to exact quality control standards, offer technical expertise, and deliver them on time. They should also demonstrate automotive sector experience delivering to major OEMs and Tier 1s.

Trusted and quality suppliers will also offer precision CNC machining integrated with extrusion services that allow for the creation of highly intricate, customised parts after they have been produced. 

In-house surface treatment capabilities are another must for automotive manufacturers as they offer versatile solutions that enhance the performance and appearance of metal surfaces.

Suppliers should offer rigorous QA systems and real-time data monitoring, as well as the ability to produce new prototypes and provide scalable production.

 

Final Considerations: Aligning Cost, Quality, and Long-Term Reliability

We hope this blog has helped bring clarity to the process of choosing an aluminium supplier. It's important to weigh up short-term savings vs long-term supplier value and take into account the total cost and the added value the right supplier can bring.

Working with a partner that is vertically integrated can also ensure a smooth transition, giving you peace of mind that the supplier can carry out everything you need from them.

If you want to reduce risk, streamline development, and gain a manufacturing partner who understands automotive timelines, contact us to discuss how BCW Engineering supports OEMs and Tier 1’s with vertically integrated aluminium solutions, backed by automotive quality systems and scalable capacity, today.

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