Aluminum & Alloys Machining
Aluminum 6061, 7075, 2024 and other aluminum alloys for aerospace, automotive, and consumer electronics applications.
Material Properties
2.7
g/cm³
660
°C
310
MPa
570
MPa
237
W/m·K
3.5 × 10⁷
S/m
Machining Recommendations
Recommended Methods
CNC milling, turning, drilling, threading
Tool Materials
Carbide tools recommended for high-speed machining
Cutting Speeds
200-400 m/min (higher than steel)
Feeds
0.1-0.3 mm/rev
Coolant
Water-soluble coolants or dry machining
Machinability
Excellent - one of the easiest metals to machine
Surface Finish
Ra 0.4-1.6 μm easily achievable
Application Case Studies
Aerospace Structural Components
Industry: Aerospace
Challenge
Aluminum 7075 parts for aircraft fuselages and wings requiring ±0.005" tolerances and 100% inspection
Solution
Utilized 5-axis machining capability and CMM verification
Result
Successfully delivered 2000+ components with AS9100D certification
Consumer Electronics Housings
Industry: Electronics
Challenge
Aluminum 6061 enclosures for smartphones, tablets, and laptops requiring anodized finish
Solution
Implemented rapid production workflow with in-house anodizing
Result
Achieved 2-week lead time for high-volume orders
Automotive Engine Blocks
Industry: Automotive
Challenge
Aluminum 356 castings for engine components requiring tight dimensional tolerances
Solution
Developed specialized machining process for cast aluminum
Result
Improved dimensional accuracy by 30% compared to previous supplier
Medical Device Frames
Industry: Medical
Challenge
Aluminum 6061 frames for surgical equipment requiring biocompatibility
Solution
Implemented specialized cleaning and passivation processes
Result
Achieved FDA approval and supplied 500+ frames annually
Industrial Heat Sinks
Industry: Industrial
Challenge
Aluminum components for thermal management requiring high thermal conductivity
Solution
Optimized fin geometry for maximum heat transfer
Result
Improved thermal performance by 25% compared to standard designs
Technical Specifications
Available Forms
- Sheets
- Rods
- Tubes
- Extrusions
- Forgings
- Castings
1mm to 300mm diameter/width
Tolerances±0.01mm to ±0.05mm
Lead Times1-3 weeks for standard orders
Quality StandardsFrequently Asked Questions
What's the difference between 6061 and 7075 aluminum?
7075 is significantly stronger (570 MPa vs 310 MPa) but less corrosion resistant and more difficult to machine. 6061 is ideal for general applications, while 7075 is preferred for aerospace and high-stress applications.
Can aluminum parts be anodized?
Yes, we offer Type II (decorative) and Type III (hard coat) anodizing services to improve corrosion resistance and wear properties. Anodizing also provides excellent color options.
What's your minimum order quantity for aluminum parts?
We accept single-piece prototypes as well as high-volume production runs. Our flexible manufacturing approach accommodates all order sizes from 1 to 100,000+ units.
How do you ensure dimensional accuracy for aluminum?
We use precision CNC machines with ±0.01mm capability, CMM verification, and SPC monitoring to ensure consistent quality across all production runs.
Can you machine aluminum extrusions?
Yes, we specialize in secondary machining of aluminum extrusions, including drilling, tapping, milling, and custom finishing to your exact specifications.
What surface finishes are available for aluminum?
We offer anodizing (Type II/III), powder coating, polishing, brushed finish, and passivation. Each finish provides different aesthetic and functional benefits.
Can you handle prototype to production transition?
Yes, we have extensive experience transitioning aluminum parts from prototype to full production. We can scale from 1 unit to 100,000+ units per month.
Do you offer design optimization for aluminum?
Yes, our engineering team can help optimize your aluminum part design for manufacturability, cost reduction, and performance improvement.
Related Services
CNC Milling
Learn more about our cnc milling capabilities
CNC Turning
Learn more about our cnc turning capabilities
CNC Drilling
Learn more about our cnc drilling capabilities
Advanced Machining
Learn more about our advanced machining capabilities
Ready to Get Started?
Contact our engineering team to discuss your metals machining requirements.