New Aluminum Page

Service Overview

Custom Aluminum Parts

eMachineShop has machined aluminum parts for over 15 years. We offer a wide range of CNC manufacturing options and often make electronic enclosures, vehicle parts, medical device components, spur gears, window frames, pipe spacers and much more.

Design and order your parts with our free CAD software or upload your own CAD file for a fast quote.

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Aluminum

is a lightweight, non-magnetic, silver-colored metal that can be formed into almost any shape. It can be rolled into thick plates for armored tanks or thin foil for wrappers. It can also be drawn into wire and made into cans.

Pure aluminum is soft and has limited strength. Small amounts of elements such as copper, magnesium and/or zinc are added to increase strength.

Aluminum is the third most abundant element in the earth’s crust after oxygen and silicon and is a comparatively new industrial metal that has been produced in commercial quantities for just over 100 years.

Properties of Aluminum

  • Excellent corrosion and chemical resistance
  • High strength-to-weight ratio
  • Good heat and electrical conductivity
  • Easily machined
  • Reflects heat and light

Aluminum is a popular choice for many metal products and components:

Auto Parts
Optical Reflectors
Cooking Utensils
Aircraft Parts
Lighting Fixtures
Medical Devices
Electronic Enclosures
Engine Parts
Handles and Knobs

Aluminum Alloys

Aluminum 6061


Has good mechanical properties and good weldability, and is one of the most common alloys for general purpose use – especially for machining.

Widely used for construction of aircraft structures, such as wings and fuselages, yacht construction, utility boats and bicycle frames and components.

Aluminum 5052


One of the most popular aluminum alloys used in sheet metal fabrication. It is readily bent, punched and sheared.

Known for its high corrosion resistance, especially in ocean water. Common applications include marine and aircraft equipment, fuel lines, street lights, household appliances, flooring panels, and railings.

Aluminum 2024


Used in applications requiring high strength to weight ratio, and has good fatigue resistance. It is not weldable and has average machinability.

Corrosion resistance is poor. Widely used in aircraft structures, especially wing and fuselage structures under tension.

Aluminum 6063


Has generally good mechanical properties, and is heat treatable. Highly weldable although strength near welds can be diminished by up to 30% if not subsequently heat treated.

Mostly used in extruded shapes for architecture, including window frames, door frames, roofs, piping, tubing and furniture.

Aluminum 7075


Strong, with good fatigue strength and average machinability, but is not weldable and has limited resistance to corrosion.

Cost is relatively high compared to other Aluminum alloys. Often used in aircraft including wings and fuselages, rock climbing equipment and bicycle components.

Machining Options

CNC Milling

Mills use rotating tools to cut material into almost any 3D shape. CNC Mills can work with tight tolerances.

Waterjet Cutting

Waterjets mainly cut sheet material into 2D parts using a high-pressure stream of water and abrasive. Waterjet cutting is suitable for most materials and yields clean edges.

CNC Turning

CNC Lathes feed cutting tools into rotating material. Turning is mainly used to produce precise, cylindrical parts.

Wire EDM

Die-Sink and Wire EDM machines create parts by using recurring sparks to remove material. Recommended for intricate designs requiring sharp inside corners and high dimensional accuracy.

Laser Cutting

Laser cutting is often used to produce 2D parts from sheet metal. A laser beam vaporizes a cut path to achieve the desired shape. Great for prototypes and short runs.

Turret Punching

CNC Turret Presses create 2D parts by rapidly punching predetermined shapes into sheet material. Cost-effective for production runs of simple metal parts.

Plasma Cutting

CNC Plasma Cutters use a high-velocity stream of ionized gas to cut parts out of sheet metal. Excellent for producing 2D parts when working with thick metal sheets.

Secondary Manufacturing

After manufacturing, parts may require additional processing. Secondary services include CNC bending, grinding, tapping, knurling and more.

Surface Finishing

Finishing processes are used to enhance appearance, surface durability, and corrosion resistance. Options include powder coating, anodizing, plating, polishing and more.

Applications and Advantages

  • Transportation: The combination of lightness, strength and malleability makes aluminum the ideal material for transportation applications. It is used in automobiles, airplanes, railways and marine applications and also for making fuel-efficient engines in cars and trucks. Its low weight reduces fuel consumption and emissions.
  • Construction: Aluminum facilitates the construction of corrosion-resistant and low maintenance cost buildings. All kinds of aluminum products are used for new construction as well as renovation and due to its strength and lightness, it is used in earthquake prone zones. It is also a good reflector of light,and is often used in lighting fixtures.
  • Vehicles: A high proportion of the shock inflicted by an automobile in a motor vehicle accident is absorbed primarily by its aluminum structure.
  • Air Travel: Strong aluminum alloys take the extreme pressures and stresses involved in high altitude flying. Wafer thin aluminum panels keep the cold out and the air in. Many internal fittings like the seating on airplanes are made from aluminum or aluminum composite in order to save weight and thus save fuel, reduce emissions and increase the aircraft’s payload.
  • Packaging and Food Processing: It is non-poisonous, which allows for non-acidic food to be safely wrapped in thin sheets like foil and cooked in vessels. Aluminum cookware is easy to lift, requires considerably less heat than stainless steel or cast iron and utensils heat up quickly and evenly.
  • Electrical Transmission Lines: This very versatile metal can be drawn into thin wires which are often used in products such as light bulbs and telephone wires. Most of the high voltage overhead transmission and distribution lines over long distances are also made of aluminum.

Resources

Cost-Savings Guide
Sheet Metal Fabrication
CNC Milling Services
Vehicle Parts