Service Overview

Custom Aluminum Parts

Forster Tool has been machining aluminum parts for over 20 years. Contract manufacturing of machine aluminum shafts, fasteners, valves, brackets, ferrules, connectors, and adapters, just to name a few.

Forster Tool will also machine any number custom Aluminum parts that you may want. As precision machining specialists, we maintain tight tolerances and dimensions.

Customers Include:

Material Overview

Aluminum is remarkable for its low density and its ability to resist corrosion through the phenomenon of passivation. Aluminum and its allows are vital to the aerospace industry.

Despite its prevalence in the environment, no known form of life uses aluminum salts metabolically, but aluminum is well tolerated by plants and animals.

Form of life uses aluminum salts metabolically, but aluminum is well tolerated by plants and animals.

Properties

Despite its prevalence in the environment, no known form of life uses aluminum salts.

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Advantages

Despite its prevalence in the environment, no known form of life uses aluminum salts.

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Commonly Machined Parts:

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

Alloys

Some of the most popular aluminum alloys we work with include:

Aluminum 6061


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 5052


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


Has good mechanical properties and good weldability, and is one of the most common alloys for general purpose use – especially for machining. Highly weldable, and is often used in extrusions and hot forging of automotive and industrial parts.

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

Aluminum 6063


Has generally good mechanical properties and is heat treatable and weldable. It is mostly used in extruded shapes for architecture, particularly window frames, door frames, roofs, piping, tubing and furniture.

Highly weldable although strength near the weld can be diminished by up to 30% without subsequent heat treating.

Aluminum 7075


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

Cost is relatively high. It is often used in aircraft including wings and fuselages, rock climbing equipment and bicycle components.

Machining Services

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.

Injection Molding

Injection Molding produces parts by forcing molten polymer material into a mold. It’s the most economical process for producing high volumes of plastic parts.

3D Printing

3D Printing (aka Rapid Prototyping) is an additive manufacturing process. It’s often used for testing designs and quick-turn low-volume 3D parts.

Compression Molding

Rubber Compression Molding creates parts by pressing a heated block of rubber into a mold. Ideal for making high volumes of simple rubber 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.

Aluminum Part Tips

  • Avoid deep holes as drilling can become difficult.
  • Request polishing of edges works very well for a glass smooth finish.
  • Use shapes that will hold well during machining, like straight edges.

Aluminum is the third most abundant element in the earth’s crust after oxygen and silicon, and is comparatively new industrial metal, widely used for less than 100 years.